Publications

Transferring technology to the private sector to help improve the competitiveness of key US industries is now an official mission of the US Department of Energy`s (DOE) defense program national laboratories. We believe that national laboratories can play an important role in addressing US industrial competitiveness. Sandia is seeking to match laboratory strengths with industry-defined market needs in targeted industrial sectors. Sandia, like other national and federal laboratories, is developing an aggressive technology transfer program. This paper provides a brief review of our program and provides a snap-shot of where we are at today.

The Plasma Facing Components (PFC) Facilities Review Panel was chartered by the US Department of Energy, Office of Fusion Energy, ITER (International Thermonuclear Experimental Reactor) and Technology Division, to outline the program plan and identify the supporting test facilities that lead to reliable, long-lived plasma facing components for ITER. This report summarizes the panel`s findings and identifies the necessary and sufficient set of test facilities required for ITER PFC development.

The CORCON-Mod3 computer code was developed to mechanistically model the important core-concrete interaction phenomena, including those phenomena relevant to the assessment of containment failure and radionuclide release. The code can be applied to a wide range of severe accident scenarios and reactor plants. The code represents the current state of the art for simulating core debris interactions with concrete. This document comprises the user`s manual and gives a brief description of the models and the assumptions and limitations in the code. Also discussed are the input parameters and the code output. Two sample problems are also given.

Gas-gun impact tests were performed on twelve rocks and rock simulants pertinent to the HYDROPLUS nuclear yield measurement program: A variety of tuffs, rhyolites, carbonates, grouts, an epoxy-alumina mixture and quartzite permafrost samples recovered in an apparently preserved frozen state from northern Canada. The present report presents results for all of these materials except for the carbonates. Two classes of impact techniques were employed for measuring equation-of-state properties for these materials. Both use velocity interferometry diagnostics. One, employing a sample-in-projectile geometry, provides high-precision Hugoniot data and continuous release trajectories for dry or water-saturated materials. The majority of the experiments were performed with this geometry. The other, employing a sample-in-target geometry, provides loading path and Hugoniot data as well as limited release data. Uncertainties in the results have been estimated by analyzing the effects of errors in observables and ancillary material properties.

The PANDA code is used to construct tabular equations of state (EOS) for the detonation products of 24 explosives having CHNO compositions. These EOS, together with a reactive burn model, are used in numerical hydrocode calculations of cylinder tests. The predicted detonation properties and cylinder wall velocities are found to give very good agreement with experimental data. Calculations of flat plate acceleration tests for the HMX-based explosive LX14 are also made and shown to agree well with the measurements. The effects of the reaction zone on both the cylinder and flat plate tests are discussed. For TATB-based explosives, the differences between experiment and theory are consistently larger than for other compositions and may be due to nonideal (finite dimameter) behavior.

The United States Department of Energy (DOE) is developing the Waste Isolation Pilot Plant (WIPP) in southeastern New Mexico for the disposal of transuranic wastes generated by defense programs. Applicable regulations (40 CFR 191) require the DOE to evaluate disposal-system performance for 10,000 yr. Climatic changes may affect performance by altering groundwater flow. Paleoclimatic data from southeastern New Mexico and the surrounding area indicate that the wettest and coolest Quaternary climate at the site can be represented by that at the last glacial maximum, when mean annual precipitation was approximately twice that of the present. The hottest and driest climates have been similar to that of the present. The regularity of global glacial cycles during the late Pleistocene confirms that the climate of the last glacial maximum is suitable for use as a cooler and wetter bound for variability during the next 10,000 yr. Climate variability is incorporated into groundwater-flow modeling for WIPP PA by causing hydraulic head in a portion of the model-domain boundary to rise to the ground surface with hypothetical increases in precipitation during the next 10,000 yr. Variability in modeled disposal-system performance introduced by allowing head values to vary over this range is insignificant compared to variability resulting from other causes, including incomplete understanding of transport processes. Preliminary performance assessments suggest that climate variability will not affect regulatory compliance.

The iron content, phase constitution, and microstructure of electrodeposited iron-zinc alloy (EZA) coatings, deposited from chloride baths, is described for as-deposited and heat-treated conditions of coatings containing bulk iron contents of 6, 8, 10, and 13 w/o. The observed influence of current density upon iron content, which in turn influences the phase constitution and microstructure of the coatings, is reported. The microstructure, composed of non-equilibrium phases that have nanometer grain sizes, is illustrated and described with respect to iron content, crystallography, and morphology. As-deposited {eta} phase coatings undergo transformations through a sequence of metastable phases when heated. The sequence of phase transformations varies with iron content, but the mechanisms of phase transformation from the as-deposited eta phase to the metastable G phase was found to be similar in 6, 8, and 10 w/o Fe coatings. Microstructural, compositional, and crystallographic changes associated with this phase transformation are discussed.

Operations which involve the dexterous manipulation of materials in hazardous environments have, in the past, been completed directly by personnel. Use of humans in these environments is under increased scrutiny due to the high cost and low productivity associated with providing protective clothing and environments. Remote systems are needed to accomplish many tasks such as the assembly of structures at remote sites when exposure of personnel to radiation and other hazards is unacceptable. Traditional remote manual operations have, unfortunately, proven to have very low productivity when compared with human operators. Recent advances in the integration of sensors and computing into the control of remotely operated equipment have shown great promise for reducing the cost of remote systems while providing safer remote systems. This paper discusses applications of such advances to remote assembly operations.

We have measured the temperature dependence of the volatility of a wide variety of Static RAMS. The temperature dependence is directly related to the memory cell design and device processing or fabrication parameters. We have seen the volatility change by {approximately}10 orders of magnitude when the absolute temperature is changed by a factor of {approximately}2. We present physical reasons for such a large temperature dependence and derive an analytical model which accurately predicts the volatility. Neutron irradiation is seen to increase the low-temperature volatility.

This report documents an improved preparation of low density microcellular carbon as well as characterization of spatial homogeneity. The report also documents the process for preparing the nficrocellular carbon from poly(acrylonitrile) raw material. A microcellular polymer precursor (0.025 g/cc) is first prepared via a solution-based process and then pyrolyzed to produce the microcellular carbon in a monolithic form (0.05 g/cc). The process improvement developed in this study permits the pore structure of the n-ficrocellular polymer precursor and the microcellular carbon to be reproduced consistently in different laboratories. Pore structure is affected by the completeness of dissolution of the polymer raw material, which variable can be adjusted via dissolution temperature or particle size of the raw material. The second topic in this report involves determining the spatial fluctuation in mass density caused by periodic, millimeter-scale bands, known as `tree rings` visible on machined surfaces of the carbon monoliths. To measure the fluctuations, we developed a high precision, spatially resolved X-ray transmission technique. The periodic bands caused less than {plus_minus}2% variation of mass density in a microcellular carbon having average density 0.041 g/cc.

Eight companys have teamed with Sandia Labs to work on five projects as part of a cooperative effort to advance the state of the ar in synthetic-diamond drill bit design and manufacture. DBS (a Baroid Company), Dennis Tool Company, Hughes Christensen Company, Maurer Engineering, Megadiamond, Security Diamond Products, Slimdril International, and Smith International. Objective of each project is to develop advanced bit technology that results in new commercial products with longer bit life and higher penetration rates in hard formations. Each project explores a different approach to synthetic-diamond cutter and bit design and, consequently, uses different approaches to developing the technology. Each of these approaches builds or the respective companies` capabilities and current product interests. Sandia`s role is to assure integration of the individual projects into a coherent program and tc provide unique testing and analytical capabilities where needed. One additional company, Amoco Production Research, will provide synthetic-diamond drill bit research expertise and field testing services for each project in the program.

This program was developed to provide a computer based framework for analytical models developed by Forrestal and co-workers [1--2] to predict depth of penetration and temporal quantities for rigid non- deforming ogive-nose projectiles penetrating into a wide variety of targets. CATNIP provides results for penetration into semi-infinite targets, but does not provide for perforation events. The program has a graphical user interface to facilitate operation so that people unfamiliar with the analytical models can use the code with a minimum of training. CATNIP runs on Apple Macintosh computers using the Hypercard program. The Hypercard program is included with the system software on all Macintosh computers. A familiarity with the Macintosh use of pointing and clicking with the mouse is assumed for the use of this program.

Sandia has developed an advanced operational control system approach, called Graphical Programming, to design, program, and operate robotic systems. The Graphical Programming approach produces robot systems that are faster to develop and use, safer in operation, and cheaper overall than altemative teleoperation or autonomous robot control systems. Graphical Programming also provides an efficient and easy-to-use interface to traditional robot systems for use in setup and programming tasks. This paper provides an overview of the Graphical Programming approach and lists key features of Graphical Programming systems. Graphical Programming uses 3-D visualization and simulation software with intuitive operator interfaces for the programming and control of complex robotic systems. Graphical Programming Supervisor software modules allow an operator to command and simulate complex tasks in a graphic preview mode and, when acceptable, command the actual robots and monitor their motions with the graphic system. Graphical Programming Supervisors maintain registration with the real world and allow the robot to perform tasks that cannot be accurately represented with models alone by using a combination of model and sensor-based control.

Part of the evaluation process that occurs during production of many complex components is performance testing of fabricated units as they are being produced. The results of these tests are used monitor the quality and reliability of the product and to contribute to the data base for reliability assessment. This paper presents an approach for designing plans for the evaluation of continuously produced product where the testing may be either destructive or non-destructive. The philosophy of the plans is to initially test a string of consecutive units at the beginning of production to show that the design and manufacturing processes conform with the required reliability. Once the product has passed the initial testing, a sampling phase is begun. If the product continues pass, a reduced sampling rate phase is used. Failures in the initial phase or the first sampling phase cause the plans to revert to the initial phase restart. If a failure occurs during the reduced sampling, the estimated failure rate is checked for concordance with the reliability requirement. This check is made to allow for continuation of sampling if the cumulative number of failures is consistent with the reliability requirement. A selection of values for the parameters of the plans and a rule for determining concordance are presented. The parameters of the plans are related to the AQL and LTPD concepts of acceptance sampling and the average number of defective units passed before a defective unit is sampled and detected.

Optoelectronics and photonics hold great potential for high data-rate communication and computing. Wide using in computing applications was limited first by device technologies and now suffers due to the need for high-precision, mass-produced packaging. The use of phontons as a medium of communication and control implies a unique set of packaging constraints that was not present in traditional telecommunications applications. The state-of-the-art in optoelectronic packaging is now driven by microelectric techniques that have potential for low cost and high volume manufacturing.

Inside this issue various short articles on current testing technology research at Sandia National Laboratories. New techniques of imaging currents in integrated circuits are described. Geomaterials testing is improved with true axial loading under high pressure. Pyroshock simulation tests electronics for space and defense. Insulated cameras get pictures of extremely hot burning fuels. Solar cell testing is improved via spectral response and laser scanning. And missile launching accomplishments are presented.

The segregation of Si impurities from the bulk to the surface of a low Cr Lot of Kovar{sup TM} (Fe-29Ni-17Co) has been investigated in order to determine the effects on the quality of the braze of Cu to these altered surfaces. It is found that oxides of Si are formed on the surface during wet hydrogen firing. Kinetics of this segregation process have been measured.

Sources of particles in a close-coupled electron cyclotron resonance (ECR) polysilicon plasma etch source include flaking of films deposited on chamber surfaces, and shedding of material from electrostatic wafer chucks. A large, episodic increase in the number of particles added to a wafer in a clean system is observed more frequently for a plasma-on than for a gas-only source condition. For polymer forming process conditions, particles were added to wafers by a polymer film which was observed to fracture and flake away from chamber surfaces. The presence of a plasma, especially when rf bias is applied to the wafer, caused more particles to be ejected from the walls and added to wafers than the gas-only condition; however, no significant influence was observed with different microwave powers. A study of effect of electrode temperatures on particles added showed that thermophoretic forces are not significant for this ECR configuration. Particles originating from the electrostatic chuck were observed to be deposited on wafers in much larger numbers in the presence of the plasma as compared to gas-only conditions.

In RF telemetry (TM) the allowable RF bandwidth limits the amount of data in the telemetered data set. Typically the data set is less than ideal to accommodate all aspects of a test. In the case of diagnostic data, the compromise often leaves insufficient diagnostic data when problems occur. As a solution, intelligence was designed into a TM, allowing it to adapt to changing data requirements. To minimize the computational requirements for an intelligent TM, a fuzzy logic inference engine was developed. This reference engine was simulated on a PC and then loaded into a TM hardware package for final testing.

This invited paper describes recently reported work on the application of magnetic force microscopy (MFM) to image currents in IC conductors [1]. A computer model for MFM imaging of IC currents and experimental results demonstrating the ability to determine current direction and magnitude with a resolution of {approximately} 1 mA dc and {approximately} 1 {mu}A ac are presented. The physics of MFM signal generation and applications to current imaging and measurement are described.

The high conductivity provided by solder closure joints of component housings is sometimes required to ensure electrical shielding of the components contained within. However, using a soldering iron to produce the solder joints can lead to charring of the insulating materials within the housing. To overcome this problem, the localized heating characteristics of laser soldering can be exploited. Feasibility of laser soldering Sn plated brass housings with a CW Nd:YAG laser has been investigated. It has been determined that laser soldering of these housings using a low solids solder flux is a viable technique and will minimize the amount of heat input to the enclosed electronic components. Metallographic analysis has shown good wetting of the solder on the housing components. Accelerated aging experiments indicate that no significant corrosion potential due to solder flux residues exists. Although a low solids flux was used to make the joints, initial results indicate that a fluxless technique can be developed to eliminate fluxes completely.

A comprehensive environment, safety and health (ES&H) program allocates an extensive portion of its resources to information collection, management, and manipulation. Much of these resources are difficult to obtain and even more costly to ensure that they are sufficiently accurate; however, a system which collects information at the point which a process begins or a material enters a facility and maintains that information throughout its entire life-cycle is a more efficient approach to providing the data necessary to meet ES&H requirements. These data requirements for all the various groups within an ES&H program are associated with the properties and interactions among materials, personnel, facilities, hazards, waste and processes. Although each group is charged with addressing a particular aspect of these properties and interactions, the information they require can be aggregated into a coherent set of common data fields. It is these common data fields that the Cradle-to-Grave Tracking and Information System (CGTIS) is designed to satisfy. Research and development laboratories such as Sandia National Laboratories (SNL) are diverse in nature and, therefore, present a complex challenge to ES&H professionals. The remainder of this paper will describe the CGTIS as envisioned and implemented at SNL, define the requirements of a complete CGTIS, and review the current status of each system module at SNL.

In the early days of microelectronics, design rules and feature sizes were large enough that sub-micron spatial resolution was not needed. Infrared or IR thermal techniques were available that calculated the object`s temperature from infrared emission. There is a fundamental spatial resolution limitation dependent on the wavelengths of light being used in the image formation process. As the integrated circuit feature sizes began to shrink toward the one micron level, the limitations imposed on IR thermal systems became more pronounced. Something else was needed to overcome this limitation. Liquid crystals have been used with great success, but they lack the temperature measurement capabilities of other techniques. The fluorescent microthermographic imaging technique (FMI) was developed to meet this need. This technique offers better than 0.01{degrees}C temperature resolution and is diffraction limited to 0.3 {mu}m spatial resolution. While the temperature resolution is comparable to that available on IR systems, the spatial resolution is much better. The FMI technique provides better spatial resolution by using a temperature dependent fluorescent film that emits light at 612 nm instead of the 1.5 {mu}m to 12 {mu}m range used by IR techniques. This tutorial starts with a review of blackbody radiation physics, the process by which all heated objects emit radiation to their surroundings, in order to understand the sources of information that are available to characterize an object`s surface temperature. The processes used in infrared thermal imaging are then detailed to point out the limitations of the technique but also to contrast it with the FMI process. The FMI technique is then described in detail, starting with the fluorescent film physics and ending with a series of examples of past applications of FMI.

Mechanistic models of aerosol decontamination by an overlying water pool during core debris/concrete interactions and spray removal of aerosols from a Mark I drywell atmosphere are developed. Eighteen uncertain features of the pool decontamination model and 19 uncertain features of the model for the rate coefficient of spray removal of aerosols are identified. Ranges for values of parameters that characterize these uncertain features of the models are established. Probability density functions for values within these ranges are assigned according to a set of rules. A Monte Carlo uncertainty analysis of the decontamination factor produced by water pools 30 and 50 cm deep and subcooled 0--70 K is performed. An uncertainty analysis for the rate constant of spray removal of aerosols is done for water fluxes of 0.25, 0.01, and 0.001 cm{sup 3} H{sub 2}O/cm{sup 2}-s and decontamination factors of 1.1, 2, 3.3, 10, 100, and 1000.

This paper describes the results of testing the MSR-20 radar and provides guidance on how this radar may be used to provide early detection and warning of approaching intruders beyond DOE facility site boundaries.