Publications

Dip coating is the primary means of depositing sol-gel films for precision optical coatings. Sols are typically multicomponent systems consisting of an inorganic phase dispersed in a solvent mixture, with each component differing in volatility and surface tension. This, together with slow coating speeds (<1cm/s), makes analysis of the coating process complicated; unlike most high-speed coating methods, solvent evaporation, evolving rheology, and surface tension gradients alter significantly the fluid mechanics of the deposition stage. We set out to understand these phenomena with computer-aided predictions of the flow and species transport fields. The underlying theory involves mass, momentum, and species transport on a domain of unknown shape, with models and constitutive equations for vapor-liquid equilibria and surface tension. Due accounting is made for the unknown position of the free surface, which locates according to the capillary hydrodynamic forces and solvent loss by evaporation. Predictions of the effects of mass transfer, hydrodynamics, and surface tension gradients on final film thickness are compared with ellipsometry measurements of film thickness on a laboratory pilot coater. Although quantitative agreement is still lacking, both experiment and theory reveal that the film profile near the drying line takes on a parabolic shape. 2 refs., 2 figs.

Sandia National Laboratories is a multiprogram engineering laboratory that serves the nation through the Department of Energy (DOE), both in its programs and those of other agencies. Major research and development responsibilities cover nuclear weapons, arms control, energy, environment and other areas of strategic importance to national security. The principal mission is to support national defense policies by ensuring that the nuclear weapon stockpile meets the highest standards of safety, security, control and military performance. In May of 1968, the Albuquerque Office of DOE (then AEC) assigned the Quality Assurance function to Sandia Laboratories on all products for which Sandia has design responsibility. The Sandia Quality Improvement Plan presents a Quality Management System that integrates the Sandia quality policies and several independent improvement processes into a cohesive structure. This structure guides day-to-day operations toward strategic objectives. The Sandia Quality Policy provides the underlying principles for the management of our research and engineering efforts and establishes our customers as the central focus of our Sandia quality improvement efforts. Operationally, these efforts are centered around quality improvement processes based on good management practices developed by AT T, and progress is measured against the Malcolm Baldridge National Quality Award criteria. Developing a comprehensive plan based on these processes requires that we determine where we are, where we want to be, and how we measure our progress. 1 fig. (JF)

A review of the objectives and accomplishments of the Computational Benchmark Problem Committee (CBPC) of the American Nuclear Society Mathematics and Computation Division is presented. A list of the benchmark problems compiled by the CBPC and published by the Argonne Code Center is included, along with a list of the problems currently under review. A brief discussion of the challenge of benchmarking in the current environment of rapidly evolving computing technology is given. 20 refs., 3 tabs.

The Distant Light Program sponsored by the Defense Nuclear Agency (RAEE) is directed toward understanding the response of electronic systems to Source Region EMP (SREMP) and will result in the development of proven system hardening and validation techniques for SREMP. This program relies very strongly on testing in above ground test (AGT) simulators such as the HERMES III gamma ray simulator at Sandia National Laboratories in Albuquerque, New Mexico. This paper describes theoretical and experimental efforts aimed at understanding the gamma ray flux produced by HERMES III in terms of its time dependence, spatial variation and spectrum. As part of this characterization, the calibration of various measuring devices must be considered. This paper describes the progress made in characterizing the HERMES III radiation output through December of 1990.

Promoted iron catalysts are commonly used for Fischer-Tropsch (F-T) synthesis. Copper, potassium and silica are frequently employed as promoter species, either singly or in combination. The number of different iron catalyst formulations which have been investigated for F-T synthesis is enormous and there does not yet appear to be a general consensus as to the optimum catalyst composition. In addition, questions regarding the effects of variations in catalyst activation and reaction conditions are still open. Because of the large number of parameters involved in the development of F-T catalysts, a great deal of work remains to be done before the factors affecting catalyst performance are fully understood. In this paper one of these factors, namely the effects of variations in activation procedure on the surface composition of iron based F-T catalysts, will be investigated. Two different catalysts were studied. The first catalyst, with a composition of 100 Fe/5 Cu/4.2 K/25 SiO{sub 2} (parts by weight) whose little variation in activity procedure (1). The second catalyst (100 Fe/3 Cu/0.2 K) displays wide variations in activity with activation procedure (2). Surface compositions of these two catalysts were measured, after the activation treatments described above, using Auger electron spectroscopy (AES). It will be shown that the variations in catalyst activity observed by Bukur, et al. (1,2), correlate well with variations in surface composition, offering insights into the optimum conditions for catalyst activation. 9 refs., 6 figs.

An analysis is made of the experimental results of a minimum-time trajectory control scheme for a two-link flexible robot. An offline optimization routine determines a minimum-time, straight-line tip trajectory which stays within the torque constraints of the motors and ends with no vibrational transients. An efficient finite-element model is used in the optimization to approximate the flexible arm dynamics. The control strategy described is used to determine the feedback gains for the position, velocity, and strain gage signals from a quadratic cost criterion based on the finite-element model linearized about the straight-line tip trajectory. These feedback signals are added to the modeled torque values obtained from the optimization routine and used to control the robot arm actuators. The results indicate that this combination of model-based and error-driven control strategies achieves a closer tracking of the desired trajectory and a better handling of modeling errors than either strategy alone.

Lithium batteries have been used in a variety of applications for a number of years. As their use continues to grow, particularly in the consumer market, a greater emphasis needs to be placed on safety and reliability. There is a useful technique which can help to design cells and batteries having a greater degree of safety and higher reliability. This technique, known as fault tree analysis, can also be useful in determining the cause of unsafe behavior and poor reliability in existing designs.

During 1990, Sandia National Laboratories initiated an advanced lead-acid battery development program supported by the US Department of Energy's Office of Energy Management. The goal is to develop a low maintenance, cost effective battery by the mid- to late 1990's that is tailored to a variety of electric utility applications. Several parallel activities are being pursued to achieve this goal. One activity seeks to quantify the economic benefits of battery storage for specific cases in candidate utility systems and identify opportunities for field demonstration of battery systems at electric utility and utility customer sites. Such demonstrations will not only generate valuable operating experience data, but will also help in building user confidence in battery storage systems. Other activities concentrate on cell- and battery-level research and development aimed at overcoming shortcomings in existing technologies, such as Valve-Regulated Lead-Acid (VRLA), or, sealed lead-acid batteries.

This paper describes the impact of paving, a new automatic mesh generation algorithm, on the analysis portion of the design process. Paving generates an all-quadrilateral mesh in arbitrary 2D geometries. The paving technique significantly impacts the analysis process by drastically reducing the time and expertise requirements of traditional mesh generation. Paving produces a high quality mesh based on geometric boundary definitions and user specified element sizing constraints. In this paper we describe the paving algorithm, discuss varying aspects of the impact of the technique on design automation, and elaborate on current research into 3D all-hexahedral mesh generation. © 1991.

A panel research experiment (PRE) was designed, built, and tested as a scaled-down model of a direct absorption receiver (DAR). The PRE is a 3-MWt DAR experiment that will allow flow testing with molten nitrate salt and provide a test bed for DAR testing with actual solar heating. In a solar central receiver system DAR, the heat absorbing fluid (a blackened molten nitrate salt) flows in a thin film down a vertical panel (rather than through tubes as in conventional receiver designs) and absorbs the concentrated solar flux directly. The ability of the flowing salt film to absorb the incident solar flux depends on the panel design, hydraulic and thermal fluid flow characteristics, and fluid blackener properties. Testing of the PRE is being conducted to demonstrate the engineering feasibility of the DAR concept. The DAR concept is being investigated because it offers numerous potential performance and economic advantages for production of electricity when compared to other solar receiver designs. The PRE utilized a 1-m wide by 6-m long absorber panel. The salt flow tests are being used to investigate component performance, panel deformations, and fluid stability. Salt flow testing has demonstrated that all the DAR components work as designed and that there are fluid stability issues that need to be addressed. Future solar testing will include steady-state and transient experiments, thermal loss measurements, responses to severe flux and temperature gradients and determination of peak flux capability, and optimized operation. In this paper, we describe the design, construction, and some preliminary flow test results of the Panel Research Experiment.

This study was undertaken in order to document and analyze the unique set of data on subsurface fracture characteristics, especially spacing, provided by the US Department of Energy's Slant Hole Completion Test well (SHCT-1) in the Piceance Basin, Colorado. Two hundred thirty-six (236) ft (71.9 m) of slant core and 115 ft (35.1 m) of horizontal core show irregular, but remarkably close, spacings for 72 natural fractures cored in sandstone reservoirs of the Mesaverde Group. Over 4200 ft (1280 m) of vertical core (containing 275 fractures) from the vertical Multiwell Experiment wells at the same location provide valuable information on fracture orientation, termination, and height, but only data from the SHCT-1 core allow calculations of relative fracture spacing. Within the 162-ft (49-m) thick zone of overlapping core from the vertical and deviated wellbores, only one fracture is present in vertical core whereas 52 fractures occur in the equivalent SHCT-1 core. The irregular distribution of regional-type fractures in these heterogeneous reservoirs suggests that measurements of average fracture spacing'' are of questionable value as direct input parameters into reservoir engineering models. Rather, deviated core provides data on the relative degree of fracturing, and confirms that cross fractures can be rare in the subsurface. 13 refs., 11 figs.

Current computer network protocols are very robust and capable of being used in a variety of different environments. Typically, the implementations of these protocols come to the user with preset parameters that provide reasonable performance for low delay- bandwidth product environments with low error rates, but these defaults do not necessarily provide optimal performance for high delay-bandwidth, high error rate environments. To provide optimal performance from the user's perspective, which is application to application, all equivalent layers of the protocol must be tuned. The key to tuning protocols is reducing idle time on the links caused by various protocol layers waiting for acknowledgments. The circuit bandwidth, propagation delay, error rate, number of outstanding packets, buffer length, number of buffers, and buffer size can all affect the observed idle time. Experiments have been conducted on test bed systems, and on live satellite and terrestrial circuits. Observations from these experiments led the authors to draw conclusions about the locations of common bottlenecks. Various aspects of network tuning and certain specific issues relating to the tuning of three protocols (DECnet, TCP/IP, NETEX) over various media types (point-to-point and broadcast) under several different conditions (terrestrial and satellite) are examined in this paper. Also described are the lessons learned about protocol and network tuning. 3 refs., 2 tabs.

A comparison of the short-transverse SCC behavior of 2090 in pH 5.5 Cl{sup {minus}} and alkaline CO{sub 3}{sup 2 {minus}}/Cl{sup {minus}} solutions using a static load smooth bar SCC technique was made. In the alkaline CO{sub 3}{sup 2 {minus}}/Cl{sup {minus}} solutions, E{sub br} for the {alpha}-Al matrix phase was 0.130 V more positive than the E{sub br} of the subgrain boundary T{sub 1} phase. In this environment, stress corrosion cracking test specimens subjected to potentials in the window defined by the two breakaway potentials failed along an intersubgranular path in less than an hour. In the Cl{sup {minus}} environment, the E{sub br} values for the two phases were nearly equal and this rapid SCC condition could not be satisfied; accordingly SCC failures were not observed. Rapid SCC failure of 2090 in CO{sub 3}{sup 2 {minus}}/Cl{sup {minus}} in our static load, constant immersion experiments appear to be related to recently reported pre-exposure embrittlement'' failures induced by immersing stressed specimens removed into ambient laboratory air after immersion in aerated NaCl solution for 7 days. In those experiments, specimens failed in less than 24 hours after removal from solution. Our polarization experiments have shown that the corrosion behavior of T{sub 1}, CO{sub 3}{sup 2 {minus}}/Cl{sup {minus}} environments, but the {alpha}-Al phase crack walls, is rapidly passivated. X-ray diffraction of the films which formed in simulated crevices suggests that this passivating film belongs to a class of compounds known as hydrotalcites.

Vertical axis wind turbine (VAWT) technology in the United States started in the early 1970s directly from the original work in Canada. The close, and very productive relationships among laboratories, universities and industry have continued since that time. This paper briefly discusses the significant technical progress and rather dramatic programmatic changes that have occurred in the past 18 to 24 months on the US side of the border. 20 refs., 14 figs.

Numerous small-scale in situ seal experiments have been emplaced in boreholes up to 38 in. in diameter at the WIPP. Seal materials include expansive salt concrete, bentonite, and crushed salt. Emplacement techniques stressed conventional technology and the use of available site personnel. Preliminary evaluation of the performance of these seals has been completed by using structural data from embedded instrumentation and fluid flow data from gas and brine flow measurements. Preliminary results suggest that submicrodarcy permeabilities can be obtained using these materials and that structural performance is satisfactory. 17 refs., 3 figs., 1 tab.

This paper describes a formal process for selecting, from a diverse set of proposed waste minimization activities, those activities that provide the greatest benefit to DOE. A methodology for evaluating and prioritizing proposals was developed to illustrate how the selection process works and what types of data are required to characterize waste minimization activities. It is clearly impossible to remove all aspects of subjective judgment from the proposal selection process. With this important consideration in mind, the methodology presented is put forth to enhance, not replace, the traditional DOE decision-making process. With relatively minor refinements, this methodology can be immediately useful to DOE Environmental Restoration and Waste Management and Defense Program organizations in preparing, evaluating, and prioritizing waste minimization proposals. 7 refs., 1 tab., 2 figs.

Our primary purpose in this test is to provide a brief general description of a few applications of various electrophoretic systems which have been investigated and have found use in various coating applications at Sandia National Laboratories. Both organic and inorganic suspensions in aqueous and non-aqueous media have been considered in these studies. Applications include high voltage insulating dielectrics, thermally conductive/electrically insulating films, adherent lubricating films, uniform photoresist films, glass coatings, and fissile uranium oxide/carbon composite films for studies of nuclear powered lasers. More recently, we have become interested in the beneficial environmental aspects of being able to provide protective polymer coatings which reduce or minimize the use of organic solvents required by traditional spray coat processes. Important practical factors which relate to film uniformity, adhesion, and composition are related to unique coating or plating capabilities and applications. 6 refs., 2 figs., 1 tab.

System dynamicists frequently encounter signals they interpret as realizations of normal random processes. To simulate these analytically and in the laboratory they use methods that yield approximately normal random signals. The traditional digital methods for generating such signals have been developed during the past 25 years. During the same period of time much development has been done in the theory of chaotic processes. The conditions under which chaos occurs have been studied, and several measures of the nature of chaotic processes have been developed. Some of the measures used to characterize the nature of dynamic system motions are common to the study of both random vibrations and chaotic processes. This paper considers chaotic processes and random vibrations. It shows contrasts between the two and situations where they are indistinguishable. The applicability of the Central Limit Theorem to chaotic processes is demonstrated. 12 refs., 8 figs.

A knowledge of the short term creep rupture behavior of Tantalum alloy T-111 is necessary to predict device integrity in the heat source section of Radioisotope Thermoelectric Generators (RTG's) at the end of service life, in the event of a fuel fire. High pressures exist in RTG's near the end of service life, these are caused by gas generation resulting from radioactive decay of the nuclear fuel. The internal pressure exerts a significant hoop stress on the T-111 alloy structural containment member. This paper analyses the short term creep behavior (rupture times up to {approximately}2 {times} 10{sup 3} hrs.) of cold worked (CW) T-111 alloy, using the existing data of Stephenson (1967). Corellations for the time to rupture, time to 1% strain and minimum creep rate have been obtained from this data using multivariable linear regression analysis. These results are compared to other short term rupture data for T-111 alloy. Finally, at the stress/temperature levels relevant to the RTG fuel fire scenario near the end of service life, the rupture time correlation for T-111 alloy predicts a rupture time of approximately 100 hrs. 10 refs., 3 figs., 1 tab.

Before the Waste Isolation Pilot Plant (WIPP) may begin service as the United States' first repository for the permanent disposal of transuranic (TRU) radioactive waste, the Department of Energy (DOE) must establish compliance with applicable environmental and safety regulations. This paper addresses one major regulation, the United States Environmental Protection Agency's (EPA) Environmental Radiation Protection Standards for Management and Disposal of Spent Nuclear Fuel, High-Level and Transuranic Radioactive Wastes, hereafter referred to as the Standard. The paper does not address compliance with other regulations. This paper summarizes Sandia National Laboratories' (SNL) early-1990 understanding of the WIPP Project's ability to comply with the long-term performance requirements set by Subpart B of the Standard, the Environmental Standards for Disposal. It also reviews the current understanding of questions critically affecting compliance and outlines the options available to assure that radionuclide releases will remain within regulatory limits. 10 refs., 3 figs.

A computational fluids dynamics scheme is presented to solve the unsteady Thin-Layer Navier-Stokes (TLNS) equations over a blunt body at high altitude, high Mach number atmospheric reentry flow conditions. This continuum approach is directed to low density hypersonic flows by accounting for non-zero bulk viscosity effects in near frozen flow conditions. The TLNS equations are solved over an axisymmetric body at zero incidence relative to the free stream. The time dependent axisymmetric governing equations are transformed into a computational plane, then cast into weak conservative form and solved using a first-order fully implicit scheme in time with second-order flux vector splitting for spatial derivatives. The physical domain is defined over representative sphere and sphere/cone geometries using a body-fitted clustered algebraic grid within a fixed domain (i.e., shock capturing). At the present time, nonequilibrium thermo-chemistry effects are not modeled. Catalytic wall, ionization and radiation effects are also excluded from the current analysis. However, the significant difference from previous studies is the inclusion of the capability to model non-zero bulk viscosity effects. The importance of bulk viscosity is reviewed and blunt body flow field solutions are presented to illustrate the potential contribution of this phenomena at high altitude hypersonic conditions. The current technique is compared with experimental data and other approximate continuum solutions. A variety of test cases are also presented for a wide range of free stream Mach conditions. 18 refs., 42 figs.

An obvious group of applications for HTS materials is microwave and millimeter wave circuitry. Besides low loss, the unique features of these materials, such as flux flow, can be exploited. We have been concentrating on the Tl-Ca-Ba-Cu-O family of materials. The film growth techniques, lithographic processing methods and the characteristics of several devices we have developed will be presented. These devices include a flux flow-based transistor with demonstrated operation at over 35 GHz, real gain in a 50 ω system and potentially useful non-linearities and impedance levels. A number of passive microwave components are under investigation to form a more complete HTS microwave technology group.

A family of silicon test chips has been developed for use in making diagnostic measurements during electronics assembly. These assembly test chips (ATC's) contain sensors that measure a number of variables associated with assembled IC degradation; including, the degree of integrated circuit (IC) corrosion, handling damage, ESD threat, ppmv moisture or humidity, mechanical stress, mobile ion density, bond pad cratering, and highspeed logic degradation. The chips in the ATC family are intended to give manufacturing feedback in four ways: direct feedback in evaluation of an assembly manufacturing line in an objective, nonintrusive way; before and after comparisons on an assembly production line when an individual process, material, or piece of equipment has been changed; resident lifetime monitor for system package aging and ongoing reliability projection; and thermal, mechanical, dc electrical, and high frequency mock-up evaluation of packaging (including multichip) schemes. © 1991 IEEE

Superconducting crystals of La2CuO4+x prepared by high-pressure oxygenation have been analyzed by Raman spectroscopy. A direct comparison of the role of excess oxygen was made by examining the same crystals with and without excess oxygen. La2CuO4+x, like nonsuperconducting La2CuO4.0, is found to have a soft phonon associated with a tetragonal-to-orthorhombic phase transition. The Ag phonons of La2CuO4.0 and La2CuO4+x occur at essentially the same frequency. At room temperature, La2CuO4+x has no well-defined peak from two-magnon scattering, unlike La2CuO4.0. However, in its phase-separated form, La2CuO4+x exhibits well-defined, two-magnon scattering. This establishes that the La2CuO4.0 phase present in La2CuO4+x at low temperatures is antiferromagnetic. La2CuO4+x samples prepared by slightly different methods are found to have differing amounts of excess oxygen, as indicated by variations in the intensity of the phonon and magnetic scattering. Certain samples of La2CuO4+x had a phonon peak at 630 cm-1 that is absent in La2CuO4.0. While a definitive assignment is not possible, the frequency of this peak is consistent with a peroxidelike species in La2CuO4+x. © 1991 The American Physical Society.

Gas contained in a rectangular laser cell of large length and small width is subjected to large, transient, spatially nonuniform, volumetric heating when pumped. The heating time scale is much longer than the time required for an acoustic wave to traverse the width but can be comparable to the time required for an acoustic wave to traverse the length. Approximate equations describing the motion are derived by applying partial acoustic filtering to the equations of motion: pressure waves traversing the width are removed while pressure waves traversing the length are retained. For a simplified one-dimensional example, a significant density variation is found across the width of the laser cell; moreover, this density variation is in good agreement with a numerical solution of the unap-proximated gas dynamic equations although the latter requires two orders of magnitude more computational time. © 1991 by ASME.