Delta is an object-oriented code architecture based on the finite element method which enables simulation of a wide range of engineering mechanics problems in a parallel processing environment. Written in C{sup ++}, Delta is a natural framework for algorithm development and for research involving coupling of mechanics from different Engineering Science disciplines. To enhance flexibility and encourage code reuse, the architecture provides a clean separation of the major aspects of finite element programming. Spatial discretization, temporal discretization, and the solution of linear and nonlinear systems of equations are each implemented separately, independent from the governing field equations. Other attractive features of the Delta architecture include support for constitutive models with internal variables, reusable ``matrix-free`` equation solvers, and support for region-to-region variations in the governing equations and the active degrees of freedom. A demonstration code built from the Delta architecture has been used in two-dimensional and three-dimensional simulations involving dynamic and quasi-static solid mechanics, transient and steady heat transport, and flow in porous media.
Candidate models and correlations describing entrainment and dispersal of core debris from reactor cavities in direct containment heating (DCH) event, are assessed against a data base of approximately 600 experiments performed previously at Brookhaven National Laboratory and Sandia National Laboratories reactor cavities was studied. Cavity geometries studied are those of the Surry and Zion nuclear power plants and scale factors of 1/42 and 1/10 were studied for both geometries. Other parameters varied in the experiments include gas pressure driving the dispersal, identities of the driving gas and of the simulant fluid, orifice diameter in the pressure vessel, and volume of the gas pressure vessel. Correlations were assessed in terms of their ability to reproduce the observed trends in the fractions dispersed as the experimental parameters were varied. For the fraction of the debris dispersed, the correlations recommended for inclusion in the CONTAIN code are the Tutu-Ginsberg correlations, the integral form of the correlation proposed by Levy and a modified form of the Whalley-Hewitt correlation. For entrainment rates, the recommended correlations are the time-dependent forms of the Levy correlation, a correlation suggested by Tutu, and the modified Whalley-Hewitt correlation.
This paper describes a product realization process developed at Sandia National Laboratories by the A-PRIMED project that integrates many of the key components of ``agile manufacturing`` (Nagel & Dove, 1992) into a complete, step-by-step, design-to-production process. For two separate product realization efforts, each geared to a different set of requirements, A-PRIMED demonstrated product realization of a custom device in less than a month. A-PRIMED used a discriminator (a precision electro mechanical device) as the demonstration device, but the process is readily adaptable to other electro mechanical products. The process begins with a qualified design parameter space (Diegert et al, 1995). From that point, the product realization process encompasses all facets of requirements development, analysis and testing, design, manufacturing, robot assembly and quality assurance, as well as product data management and concurrent engineering. In developing the product realization process, A-PRIMED employed an iterative approach whereby after each build, the process was reviewed and refinements were made on the basis of lessons learned. This paper describes the integration of project functions and product realization technologies to develop a product realization process that on repeated iterations, was proven successful.
We recently described a near-surface imaging scheme that employs disilanes and a bilayer resist scheme which together dramatically improve silicon contrast. A relatively thin 0.25 to 0.1 {mu}m imaging layer of a chemically amplified photo-crosslinking resist (Shipley XP-8844 or XP-9472) is spin coated on top of a thicker (0.25-0.5 {mu}m) layer of hard-baked resist (such as Shipley MP-1807). This bilayer scheme improves silicon contrast and provides additional advantages such as providing a planarizing layer and a processing layer.
The US Department of Energy conducted the 1994 Fernald (Ohio) field characterization demonstration project to evaluate the performance of a group of both industry-standard and proposed alternative technologies in describing the nature and extent of uranium contamination in surficial soils. Detector stability and measurement reproducibility under actual operating conditions encountered in the field is critical to establishing the credibility of the proposed alternative characterization methods. Comparability of measured uranium activities to those reported by conventional, US Environmental Protection Agency (EPA)-certified laboratory methods is also required. The eleven (11) technologies demonstrated included (1) EPA-standard soil sampling and laboratory mass-spectroscopy analyses, and currently-accepted field-screening techniques using (2) sodium-iodide scintillometers, (3) FIDLER low-energy scintillometers, and (4) a field-portable x-ray fluorescence spectrometer. Proposed advanced characterization techniques included (5) alpha-track detectors, (6) a high-energy beta scintillometer, (7) electret ionization chambers, (8) and (9) a high-resolution gamma-ray spectrometer in two different configurations, (10) a field-adapted laser ablation-inductively coupled plasma-atomic emission spectroscopy (ICP-AES) technique, and (11) a long-range alpha detector. Measurement reproducibility and the accuracy of each method were tested by acquiring numerous replicate measurements of total uranium activity at each of two ``standard sites`` located within the main field demonstration area. Meteorological variables including temperature, relative humidity. and 24-hour rainfall quantities were also recorded in conjunction with the standard-sites measurements.
Some dynamic environments are characterized by time histories that are not Gaussian. A more accurate simulation of these environments can be generated if a realization of a non Gaussian time history can be reproduced which has a specified auto spectral density (also called power spectral density) and a specified skewness and kurtosis (not necessarily the skewness and kurtosis of a Gaussian time history). The mean square of the waveform is reproduced if the spectrum is reproduced. Modern waveform reproduction techniques can be used to reproduce the realized waveform on an electrodynamic or electrohydraulic shaker. A method is presented for the generation of realizations of zero mean non Gaussian random time histories with a specified auto spectral density, skewness, and kurtosis. Kurtosis, defined in this paper as E[{chi}{sup 4}]/E{sup 2}[{chi}{sup 2}], greater than 3 can be realized. Realizations of the random process are generated with a generalization of shot noise.
This report introduces and evaluates system analysis tools that were developed, or are under development, for the Robotics Technology Development Program (RTDP). Additionally, it discusses system analysis work completed using these tools aimed at completing a system analysis of the retrieval of waste from underground storage tanks on the Hanford Reservation near Richland, Washington. The tools developed and evaluated include a mixture of commercially available tools adapted to RTDP requirements, and some tools developed in house. The tools that are included in this report include: a Process Diagramming Tool, a Cost Modeling Tool, an Amortization Modeling Tool, a graphical simulation linked to the Cost Modeling Tool, a decision assistance tool, and a system thinking tool. Additionally, the importance of performance testing to the RTDP and the results of such testing executed is discussed. Further, the results of the Tank Waste Retrieval (TWR) System Diagram, the TWR Operations Cost Model, and the TWR Amortization Model are presented, and the implication of the results are discussed. Finally, the RTDP system analysis tools are assessed and some recommendations are made regarding continuing development of the tools and process.
In order to create sub micron vias between metal layers on silicon IC circuits, the tungsten filled via processes have been in a constant state of development over the past 15 years. Processing is complex, expensive, and difficult to reproduce. The introduction of galvanic cells, via undercutting, and exposed plugs are just some of the plagues that have hit several users of the technology. Discussed in this paper is an alternative approach to the complex tungsten filled via interconnect process. The proposed process yields well at sub micron geometries, is easy to perform, and is inexpensive compared to the tungsten filled via process. Contact resistance improves greatly over the standard tungsten process. The test run achieved a mean value of 0.25 ohms per via compared to historic tungsten process that yields 0.4 ohms per via. The distribution was also excellent with sigma recorded at 0.025 ohms per via.
We report the threshold characteristics of small oxide-confined vertical-cavity surface emitting lasers. Abrupt threshold transitions 105 times the spontaneous emission background are obtained at injection currents as low as 470 nanoampere.
Military specified, ceramic packaged and radiation hardened components will disappear before the end of the century. The only long-term sustainable alternative may well be to use plastic packaged Commercial Components. The material in this report comes from the Defense Logistics Agency sponsored Plastic Package Availability Program and from an AT and T field reliability study. It summarizes Case Studies from companies which have been building and fielding highly reliable commercial and DOD military systems using plastic commercial components. Findings are, that when properly selected commercial components are operated within the true limitations of their design and packaging, they are as reliable as today`s Mil Spec components. Further, they offer cost, space and weight savings, shared manufacturing and field test experience with industry, and access to the most modern technology. Also reported are potential problems that may be encountered when using commercial components, their long term storage and use reliability characteristics, recommended design processes and supplier selection practices, commercial best business practices, and a semiconductor manufacturer`s view of the military`s switch to commercial plastic microcircuits.
This paper outlines the use of a Failure Modes and Effects Analysis for the safety assessment of a robotic system being developed at Sandia National Laboratories. The robotic system, The Weigh and Leak Check System, is to replace a manual process at the Department of Energy facility at Pantex by which nuclear material is inspected for weight and leakage. Failure Modes and Effects Analyses were completed for the robotics process to ensure that safety goals for the system had been meet. These analyses showed that the risks to people and the internal and external environment were acceptable.
We have demonstrated a new semiconductor laser device that may be useful in high speed characterization of cell morphology for diagnosis of disease. This laser device has critical advantages over conventional cell fluorescence detection methods since it provides intense, monochromatic, low divergence light signals that are emitted from lasing modes confined by a cell. Further, the device integrates biological structures with semiconductor materials at the wafer level to reduce size and simplify cell preparation. This microcavity semiconductor laser comprises a vertical cavity surface-emitting semiconductor, to provide gain and feedback for light confined by cells, and a dielectric mirror to close the cavity. Transparent cells loaded into the cavity act as dielectric waveguides to define transverse electromagnetic modes. Light emitted from the microcavity can be resolved into narrow spectral modes, high-contrast/coherent light images, or time-dependent pulses that reveal cell morphology and size. We have used this laser device as a cytometer in two basic configurations. First, as a probe of individual cells by spectral analysis of cell modes. Second, as scanning cytometer for rapidly probing large numbers of cells by pulse height spectroscopy.
This report provides an Executive Summary of the various elements of the Materials Sciences Program which is funded by the Division of Materials Sciences, Office of Basic Energy Sciences, U.S. Department of Energy at Sandia National Laboratories, New Mexico.
This report pertains to a Laboratory Directed Research and Development project which was funded for FY94 and FY95. The goal was to develop building blocks for small, cheap sensors that use optical spectroscopy as a means of detecting chemical analytes. Such sensors can have an impact on a wide variety of technologies, such as: industrial process control, environmental monitors, chemical analysis in medicine, and automotive monitors. We describe work in fabricating and demonstrating a waveguide/grating device that can serve as the wavelength dispersive component in a miniature spectrometer. Also, we describe the invention and modeling of a new way to construct an array of optical interference filters using sub-wavelength lithography to tune the index of refraction of a fixed Fabry-Perot cavity. Next we describe progress in more efficiently calculating the fields in grating devices. Finally we present the invention of a new type of near field optical probe, applicable to scanning microscopy or optical data storage, which is based on a circular grating constructed in a waveguide. This result diverges from the original goal of the project but is quite significant in that it promises to increase the data storage capacity of CD-ROMs by 10 times.
This work gives a proof of convergence for a randomized learning algorithm that describes how anoles (lizards found in the Carribean) learn a foraging threshold distance. This model assumes that an anole will pursue a prey if and only if it is within this threshold of the anole`s perch. This learning algorithm was proposed by the biologist Roughgarden and his colleagues. They experimentally confirmed that this algorithm quickly converges to the foraging threshold that is predicted by optimal foraging theory our analysis provides an analytic confirmation that the learning algorithm converses to this optimal foraging threshold with high probability.
Space reactor safety activities and decisions have evolved over the last decade. Important safety decisions have been made in the SP-100, Space Exploration Initiative, NEPSTP, SNTP, and Bimodal Space Reactor programs. In addition, international guidance on space reactor safety has been instituted. Space reactor safety decisions and practices have developed in the areas of inadvertent criticality, reentry, radiological release, orbital operation, programmatic, and policy. In general, the lessons learned point out the importance of carefully reviewing previous safety practices for appropriateness to space nuclear programs in general and to the specific mission under consideration.
Silicon solar cell efficiencies of 17.1%, 16.4%, 14.8%, and 14.9% have been achieved on FZ, Cz, multicrystalline (mc-Si), and dendritic web (DW) silicon, respectively, using simplified, cost-effective rapid thermal processing (RTP). These represent the highest reported efficiencies for solar cells processed with simultaneous front and back diffusion with no conventional high-temperature furnace steps. Appropriate diffusion temperature coupled with the added in-situ anneal resulted in suitable minority-carrier lifetime and diffusion profiles for high-efficiency cells. The cooling rate associated with the in-situ anneal can improve the lifetime and lower the reverse saturation current density (Jo), however, this effect is material and base resistivity specific. PECVD antireflection (AR) coatings provided low reflectance and efficient front surface and bulk defect passivation. Conventional cells fabricated on FZ silicon by furnace diffusions and oxidations gave an efficiency of 18.8% due to greater short wavelength response and lower Jo.
With the eventual phase-out of chlorofluorocarbons and hydrochlorofluorocarbons, and restrictive regulations concerning the use of other volatile organic compounds as cleaning solvents, it is essential to seek new, environmentally acceptable cleaning processes. We are investigating supercritical carbon dioxide (CO2) as an alternative solvent for precision cleaning of machined metal parts in governmental and industrial cleaning processes. The compatibility of metals in supercritical-fluid cleaning media with respect to corrosion must be addressed. In this work, a screening study of the corrosive effects of supercritical CO2 and several supercritical cosolvents on selected metals was conducted. Sample coupons of stainless steel (grades 304LSS, 316SS), aluminum (grades 2024, 6061, 7075), carbon steel (1018), and copper (CDA 101) were statically exposed to pure supercritical CO2, water-saturated supercritical CO2, 10 wt % methanol/CO2 cosolvent, and 4 wt % tetrahydrofurfuryl alcohol (THFA)/CO2 at 24,138 kPa (3500 psig) and 323 K (50 °C) for 24 h. Gravimetric analysis and magnified visual inspection of the coupons were performed before and after the exposure tests. Surface analyses including electron microprobe analysis (EMPA), X-ray photoelectron spectroscopy (XPS), and Auger electron spectroscopy (AES) were done where visual and gravimetric changes were indicative of corrosive attack. The metal alloys were found to be compatible with the supercritical test media barring a few exceptions. Corrosive attack was observed on 1018 carbon steel in the water-saturated CO2 environment, and also on 2024 aluminum and CDA 101 copper, both in the 10 wt % methanol-CO2 cosolvent. The results of all compatibility testing are reported, and hypotheses are formed in an attempt to explain possible corrosion mechanisms.
A survey of existing data has been completed in order to examine the hazards to people exposed on the ground and to in-flight aircraft by debris produced during high-altitude, rocket-boosted flight tests. These data were then analyzed to quantify the particle sizes and energy levels below which the fragments no longer pose a hazard. The survey results are presented here and recommendations made regarding the minimum energy levels and minimum particle size that need be considered in a flight safety analysis.
Metastable SiGe films were grown by MBE on Si (001) substrates and annealed to promote varying degrees of partial relaxation. X-ray diffraction reciprocal-space analysis was then used to monitor the structural evolution of the displacement fields of the dislocation array with increasing misfit density. The diffuse-x-ray-scattering patterns of the dislocated heterolayers were compared with lineal-misfit densities determined by defect etching, leading us to develop a geometric model which provides a framework for understanding the early-stage evolution of the displacement fields of the dislocation array, and which also explicitly links diffuse x-ray intensity to misfit density. At low misfit density, the diffuse intensity arises from two-dimensional displacement fields associated with single-nonoverlapping dislocations. As misfit density increases, the displacement fields of individual dislocations increasingly overlap producing three-dimensional displacements. The evolving diffuse intensity reflects the transition from 2-D to 3-D displacement fields. Finally, it is demonstrated that the diffuse x-ray intensity of the strained epilayer can be used to accurately measure lineal misfit-dislocation densities from 400 to 20,000 lines/cm.
National Electronic Packaging and Production Conference-Proceedings of the Technical Program (West and East)
Frear, D.R.
The most commonly used solder for electrical interconnects in electronic packages is the near eutectic 60Sn-40Pb alloy. This alloy has a number of processing advantages (suitable melting point of 183°C and good wetting behavior). However, under conditions of cyclic strain and temperature (thermomechanical fatigue) the microstructure of this alloy undergoes a heterogeneous coarsening and failure process that makes the prediction of solder joint lifetime complex. A finite element simulation methodology to predict solder joint mechanical behavior, that includes microstructural evolution, has been developed. The mechanical constitutive behavior was incorporated into the time dependent internal state variable viscoplastic model through experimental creep tests. The microstructural evolution is incorporated through a series of mathematical relations that describe mass flow in a temperature/strain environment. The model has been found to simulate observed thermomechanical fatigue behavior in solder joints.
The FD-TD method and the Berenger Perfectly Matched Layer (PML) absorbing condition are applied to the modeling of a 32-element patch array. Numerical results for the return loss at the array feed are presented and compared to measured results for the purpose of model validation.
One of the Department of Energy's programs for assuring the safety and security of nuclear weapons, nuclear power plants and hazardous material containers is discussed. A Fire Science and Technology program has been established at Sandia National Laboratories to integrate those technologies needed for creating validated numerical simulations of real fires and the response by real objects exposed to fire. This paper describes Sandia's program for integrating fire science and technology into predictive capabilities which provide engineering solutions to high-consequence fire-related problems. The integration of solid materials and fire issues will be emphasized.