Publications

Welcome to this first issue of Manufacturing Technology, one of three new technology bulletins published at Sandia National Laboratories in which we seek to share information with US industry about applications of technology. Inside this issue: industry/DOE/Sandia agreement to strengthen specialty metals competitiveness; silicon micromachining produces microscopic parts; Sandia develops state-of-the-art capacitor winding machine; new robotic system spells finis to manual edge finishing; and milling assistant speeds numerically controlled machine programming.

This paper discusses several methods to detect the presence of and track the frequency of a chirping signal in broadband noise. The dynamic behavior of each of the methods is described and tracking error bounds are investigated in terms of the chirp rate. Frequency tracking and behavior in the presence of varying levels of noise are illustrated in examples. 11 refs., 29 figs.

The authors have developed and applied a methodology to evaluate and prioritize proposed waste minimization activities affecting Department of Energy (DOE) programs. The approach provides a systematic and defensible method for selecting a set of waste minimization proposals that maximizes the benefits to DOE while maintaining costs within a specified budget. The report discusses the development of a structured set of evaluation criteria to characterize waste minimization issues; techniques for documenting the anticipated and potential costs, risks, and benefits of waste minimization proposals; and a method of translating disparate data into a figure of merit for each proposal. A test case demonstration of this prioritization approach was applied to proposals currently being considered at two DOE weapons production facilities. Recommendations are provided for combining this approach with the existing DOE proposal selection process. 9 refs., 9 figs., 3 tabs.

NIRVANA is an effort to standardize electrical computer-aided design workstations at Sandia National Laboratories in Albuquerque, New Mexico. The early effect of this project will be the introduction of at least 60 new engineering workstations at Sandia National Laboratories. Albuquerque, and at Allied Signal, Kansas City Division. These workstations are expected to begin arriving in September 1990. This paper proposes a design and outlines the requirements for a network to support the NIRVANA project. The author proposes a near-term network design, describes the security profile and caveats of this design, and proposes a long-term networking strategy for NIRVANA. 6 refs., 7 figs.

This WIPP Bin-Scale CH TRU Waste Test program described herein will provide relevant composition and kinetic rate data on gas generation and consumption resulting from TRU waste degradation, as impacted by synergistic interactions due to multiple degradation modes, waste form preparation, long-term repository environmental effects, engineered barrier materials, and, possibly, engineered modifications to be developed. Similar data on waste-brine leachate compositions and potentially hazardous volatile organic compounds released by the wastes will also be provided. The quantitative data output from these tests and associated technical expertise are required by the WIPP Performance Assessment (PA) program studies, and for the scientific benefit of the overall WIPP project. This Test Plan describes the necessary scientific and technical aspects, justifications, and rational for successfully initiating and conducting the WIPP Bin-Scale CH TRU Waste Test program. This Test Plan is the controlling scientific design definition and overall requirements document for this WIPP in situ test, as defined by Sandia National Laboratories (SNL), scientific advisor to the US Department of Energy, WIPP Project Office (DOE/WPO). 55 refs., 16 figs., 19 tabs.

Calculations have been performed with the HULL hydrocode to study ground shock effects for multiple earth penetrator weapon (EPW) bursts in hexagonal-close-packed (HCP) arrays. Several different calculational approaches were used to treat this problem. The first simulations involved two-dimensional (2D) calculations, where the hexagonal cross-section of a unit-cell in an effectively-infinite HCP array was approximated by an inscribed cylinder. Those calculations showed substantial ground shock enhancement below the center of the array. To refine the analysis, 3D unit-cell calculations were done where the actual hexagonal cross-section of the HCP array was modelled. Results of those calculations also suggested that the multiburst array would enhance ground shock effects over those for a single burst of comparable yield. Finally, 3D calculations were run in which an HCP array of seven bursts was modelled explicitly. In addition, the effects of non-simultaneity were investigated. Results of the seven-burst HCP array calculations were consistent with the unit-cell results and, in addition, provided information on the 3D lethal contour produced by such an array.

Analyses of the internal argon gas concentrations monitored on surveillance units of the W84 indicates that field aging of this weapon for times up to {approximately}4 years does not lead to important increases in the rate at which water leaks into the interior of the weapon. This implies that the EPDM environmental seals used on the W84 do not age significantly over this time period. By comparing the percentages of oxygen and argon in the internal atmosphere, an estimate of the oxygen consumption rate is made for a typical W84 unit. The argon gas analysis approach is then applied to the W88, which is sealed with a new EPDM material. Predictive expressions are derived which relate the anticipated argon gas concentrations of future, field-returned units to their water leakage rates. The predictions are summarized in convenient plots, which can be immediately and easily applied to surveillance data as reported. Since the argon approach is sensitive enough to be useful over the entire lifetime of the W88, it can be used to point out leaking units and to determine whether long-term aging has any significant effect on the new EPDM material. 11 refs., 10 figs., 3 tabs.

The Robotic Edge Finishing Laboratory at Sandia National Laboratories is developing four areas of technology required for automated deburring, chamfering, and blending of machined edges: (1) the automatic programming of robot trajectories and deburring processes using information derived from a CAD database, (2) the use of machine vision for locating the workpiece coupled with force control to ensure proper tool contact, (3) robotic deburring, blending, and machining of precision chamfered edges, and (4) in-process automated inspection of the formed edge. The Laboratory, its components, integration, and results from edge finishing experiments to date are described here. Also included is a discussion of the issues regarding implementation of the technology in a production environment. 24 refs., 17 figs.

A series of impact experiments on a composite propellant, an energetic propellant, and their simulants was recently completed using a light-gas gun. Previous experiments were done to obtain Hugoniot data, to investigate the pressure threshold at which a reaction occurs, and to measure spall damage at various impact velocities. The present studies measured the attenuation of shock waves in these materials, completing the shock characterization needed for material modeling. An initial impulse of 2.0 GPa magnitude and {approximately}0.6 {mu}s duration was imposed upon samples of various thicknesses. VISAR was used to measure the free-surface velocity at the back of the samples; these data were used to generate a curve of shock-wave attenuation versus sample thickness for each material. Results showed that all four materials attenuated the shock wave very similarly. Material thicknesses of 3.0, 7.62, 12.7, and 19.0 mm attenuated the shock wave {approximately}16%, 33%, 50%, and 66% respectively. 14 refs., 12 figs., 4 tabs.

This report concerns the evaluation of the Stellar Systems Inc. E-Field intrusion detection system Series 800 control unit and the 5000 Series hardware components. Included are functional descriptions, installation procedures, testing procedures, and testing/operational results. 35 figs.

The WhiteStar project provides design engineers with needed part design data. WhiteStar encourages the use of preferred parts by providing a user-convenient parts database. This report shows selections the user makes in order to obtain information on a particular part. 15 figs.

This report investigates the behavior of a family of finite element error estimators based on projected stresses, i.e., continuous stresses that are a least squared error fit to the conventional Gauss point stresses. An error estimate based on element force equilibrium appears to be quite effective. Examples of adaptive mesh refinement for a one-dimensional problem are presented. Plans for two-dimensional adaptivity are discussed. 12 refs., 82 figs.

This report describes the design intent, design considerations, system use, development, product characteristics, and early production history of the MC3714 Thermal Battery. This battery has a required operating life of 146 s above 24.0 V with a constant current load of 0.5 A. It is activated when the MC3830 Actuator initiates the WW42C1 Percussion Primer in the battery. The MC3714 employs the Li(Si)/LiCl-CCl/lithiated FeS{sub 2} electrochemical system. The battery is a hermetically sealed right-circular cylinder with an antirotation ring brazed to the base of the cylinder. The battery is 50 mm long and 38.1 mm in diameter. The mass of the battery is 165 g. The battery was designed and developed to provide the power for the W82 JTA Telemetry System. 8 refs., 12 figs., 11 tabs.

Infrared video thermograms of a portion of the surface of graphite limiters in Textor were taken during several disruptions. Estimates of the deposition power density were made by comparison of the observed temperature histories with those calculated from a numerical thermal conduction model. It was found that the heat flux, at the observed locations, often occurred in sharp submillisecond bursts, the magnitudes of which were much larger than the heat flux density averaged over the whole disruption. 5 refs., 4 figs.

The mechanical properties of a coring from the bottom of the MOSAIK KfK cask were determined as a function of through wall position for the 21 cm thick section. The elastic moduli were determined from ultrasonic velocity measurements. The standard tensile properties were determined as a function of strain rate at {minus}29{degree}C. The Charpy impact behavior was measured as a function of temperature from {minus}100 to {plus}100{degree}C. The fracture toughness was determined for both static and elevated loading rates (at {minus}29{degree}C). In addition to these mechanical properties, the variation in microstructure and composition with position in the coring is reported. The mechanical properties provide the essential information for the stress analysis modeling of the behavior of the cask during a drop test which will be conducted to simulate a very severe accident condition. The results from the elevated loading rate fracture toughness tests are used to suggest the severity of the flaws that should be introduced into the cask for the sequential series of drops which are scheduled to begin in March 1990. 24 refs., 16 figs., 6 tabs.

Recently an appreciable number of continuous release profiles have been measured from dynamic experiments with geological materials. For each material an empirical generalization of the available release curves may be constructed to allow easy application of the experimental data to problems in much the same way as a linear shock velocity -- particle velocity fit allows easy application of Hugoniot data. This generalization is made in two steps. The first is to compute the Eulerian axial modulus at the Hugoniot pressure and its first three pressure derivatives along the release for each test. This corresponds to a partial Taylor series of the axial modulus, which integrates to give a very close match to the original release. An alternative formulation, which takes volume as the independent variable, fails because that Taylor series does not converge with the rapidity needed for these calculations. The second step is to plot each of these quantities against the Hugoniot pressure for the suite of tests, and fit these data. A release from an arbitrary pressure within the general range of the experimental data may be computed by using the interpolated modulus and its interpolated derivatives. This generalization, which allows volume to be computed as a function of pressure, reproduces the experimental curves fairly well. We present the results of applying this technique to release data for Mini Jade 2 grout, and briefly compare these results with those from several Nevada Test Site tuffs, saturated and dry Indiana Limestone, and aluminum. Finally, we use the generalized Mini Jade 2 data to solve a sample problem, that of estimating the error produced by making the release = Hugoniot'' assumption in the analysis of ground motion gauges in an underground test. 12 refs., 14 figs., 5 tabs.

The tests described in this report were conducted to obtain information on the effects target characteristics have on portal type metal detector response. A second purpose of the tests was to determine the effect of detector type and settings on the detection of the targets. Although in some cases comparison performance of different types and makes of metal detectors is found herein, that is not the primary purpose of the report. Further, because of the many variables that affect metal detector performance, the information presented can be used only in a general way. The results of these tests can show general trends in metal detection, but do little for making accurate predictions as to metal detector response to a target with a complex shape such as a handgun. The shape of an object and its specific metal content (both type and treatment) can have a significant influence on detection. Thus it should not be surprising that levels of detection for a small 100g stainless steel handgun are considerably different than for detection of the 100g stainless steel right circular cylinder that was used in these tests. 7 figs., 1 tab.

A steam blowdown test was performed at the Surtsey Direct Heating Test Facility to test the steam supply system and burst diaphragm arrangement that will be used in subsequent Surtsey Direct Containment Heating (DCH) experiments. Following successful completion of the steam blowdown test, the HIPS-10S (High-Pressure Melt Streaming) experiment was conducted to demonstrate that the technology to perform steam-driven, high-pressure melt ejection (HPME) experiments has been successfully developed. In addition, the HIPS-10S experiment was used to assess techniques and instrumentation design to create the proper timing of events in HPME experiments. This document discusses the results of this test.

Sandia is committed to a policy of adherence to all US export control laws and regulations. The export of technical data, software, or hardware will be accomplished in accordance with Federal agencies` export control regulations. Sandia employees at all levels are responsible to ensure that exports are accomplished in compliance with export control laws and regulations. This booklet explains these export control laws and regulations.

High pressure Hugoniot and release equation of state data are provided for samples from three Nevada Test Site rock units. These are the MC-2 and MC-3 members of the P-Tunnel (Paintbrush) Tuff and the N-Tunnel (Tunnel Bed) Tuff. The technique used provides continuous release trajectories from the Hugoniot pressure down to approximately half of the Hugoniot pressure. Hugoniot and release results for the MC-2 and MC-3 members are very similar, while the Hugoniot of the N-Tunnel Tuff is somewhat stiffer, consistent with the higher density of this tuff as tested. The materials were tested at less than full saturation; correcting for this tends to narrow the difference in the properties of the two rock types sufficiently that the data do not provide a basis for predicting significantly different groundshock properties of the three units, leaving unexplained the anomalously high groundshock attenuation observed in the Mission Cyber event (performed in the MC-2 unit of the Paintbrush tuff). 26 refs., 61 figs., 9 tabs.

During rapid solidification, nonequilibrium interface kinetics alter the predictions of the Mullins-Sekerka theory for the stability of a planar interface against cellular breakdown. The velocity-dependence of the partition coefficient and of the Sn concentration at the onset of cellular breakdown have been measured during pulsed laser melting of Si--Sn alloys. The Mullins-Sekerka theory is modified by inserting a velocity-dependent partition coefficient and a velocity-dependent slope of the kinetic liquids,'' both of which are extracted from the Continuous Growth Model for interface kinetics. These nonequilibrium interface kinetic effects increase the predicted critical concentration for cellular breakdown by two orders of magnitude for Sn in Si, and account fairly well for the experimental results. 34 refs., 3 figs.

Several models of runaway electron generation during a disruption are described and applied to the problem of determining the radiation loss and energy limit of runaway electrons. In particular the prediction of orbits and energy limits for proposed ITER design are discussed. It was found that resonance between the electron gyrofrequency and the fundamental ripple frequency can lead to large synchrotron radiation losses and create an upper bound on runaway energy. Interactions with the second harmonic of the ripple field are very sensitive to ripple amplitude and may lead to a further reduction in runaway energy. In ITER this effect can limit the runaway energy to values of 270 MeV. A lump circuit model of the plasma can be used to determine the coupled interactions of the runaway currents with the plasma and control circuit currents. Depending on what is assumed about the perpendicular energy of the runaway electrons. Maximum values of runaway energy predicted for ITER are in the range of 35 to 120 MeV. 4 refs., 15 figs.

A bilateral teleoperation system consists of a local master manipulator and a remotely located slave manuipulator. Generalized velocity commands are sent forward from the master to the slave, and generalized force/torque information is reflected'' back from the slave to the master. Often there is a transmission delay incurred when communicating between the two subsystems which causes instability in the bilateral teleoperator. Recently, a solution for this instability problem was found, based on mimicking the behavior of a lossless transmission line. Although this solution provides steady-state force and velocity tracking, it does not provide steady-state force and position tracking, as is desired for bilateral teleoperation. In this paper a modification is given to the basic control law which overcomes this difficulty. 13 refs., 6 figs., 1 tab.

This document serves as the proceedings for the annual project review meeting held by Sandia's Photovoltaic Cell Research Division and Photovoltaic Technology Division. It contains information supplied by each organization making a presentation at the meeting, which was held August 7 through 9, 1990 at the Sheraton Hotel in Albuquerque, New Mexico. Sessions were held to discuss national photovoltaic programs, one-sun crystalline silicon cell research, concentrator silicon cell research, concentrator 3-5 cell research, and concentrating collector development.

The Center for Compound Semiconductor-Technology (CCST)at Sandia National Laboratories encompasses the full range of required activities--theoretical and experimental solid-state physics, materials science, crystal growth, device design, and fabrication--to develop the next generation of electronic and optoelectronic devices. Semiconductor electronics are vital to the communications and computer industries and to the nation's defense. Compound semiconductors offer very high-speed electronics and integrated optical and electronic capabilities not available with silicon, and will underlie future electronic, optoelectronic, and photonic technologies. The purpose of the CCST is to perform collaborative research generic to electronic and optoelectronic technologies in compound semiconductors. The CCST also includes related research in high-temperature superconducting electronics and hybrid superconductor-semiconductor devices. Facilities in the CCST include extensive molecular-beam epitaxy and metal-organic chemical vapor deposition crystal growth capabilities, a 400-keV ion implanter, and a new 3700 net square foot, class 1000/100 clean room with state-of-the-art processing equipment. Addition of an electron-beam lithography system to permit fabrication of devices with feature sizes below 100 nm is planned for the near future.