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The use of hybrid-power sources for improved performance with pulsed loads

Roth, E.P.; Nagasubramanian, G.

Electrical characteristics of hybrid power sources consisting of Li-ion cells and double layer capacitors were studied at 25 C and {minus}20 C. The cells were initially evaluated for pulse performance and then measured in hybrid modes of operation. Cells manufactured by Panasonic delivered pulses up to 3A and cells from A and T delivered 4A at 25 C before cell capacity dropped. Measured cell resistances were 0.15 ohms and 0.12 ohms, respectively. These measurements were repeated at {minus}20 C. Direct coupling of the cells and capacitors (dumb hybrid) extended the pulse limits to 5.6A using the Panasonic cells and 9A for the A and T cells. Operation in a smart hybrid mode using uncoupled cell/capacitor discharge allowed full cell capacity usage at 25 C and showed a factor of 5 improvement in delivered capacity at {minus}20 C.

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Development of a high-voltage, high-power thermal battery

Guidotti, Ronald A.

The power requirements for an inverter application were specified to be 500 V at 360 A, or 180 kW per each of six 1-s pulses delivered over a period of 10 minutes. Conventional high-power sources (e.g., flywheels) could not meet these requirements and the use of a thermal battery was considered. The final design involved four, 125-cell, 50-kW modules connected in series. A module using the LiSi/CoS{sub 2} couple and all-Li (LiCI-LiBr-LiF minimum-melting) electrolyte was successfully developed and tested. A power level of over 40 kW was delivered during a 0.5-s pulse. This translates into a specific power level of over 9 kW/kg or 19.2 kW/L delivered from a module. The module was still able to deliver over 30 kW during a 1-s pulse after 10 minutes.

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A study of the ignition processes in a center-hole-fired thermal battery

Guidotti, Ronald A.

The ignition processes that take place during activation of a 16 cell, center hole fired thermal battery were examined by monitoring the voltage of each cell during activation. The average rise time of each cell to a voltage of 1.125 V was determined for the LiSi/LiCl-LiBr-LiF/FeS{sub 2} electrochemical system. The effects of heat pellet composition, center hole diameter, and the load on the activation parameters were examined for three different igniters. A large variability in individual cell performance was evident along with cell reversal, depending on the location of the cell in the stack. It was not possible to draw detailed statistical information of the relative ignition sequence due to the intrinsic large scatter in the data.

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Aeroelastic tailoring in wind-turbine blade applications

Veers, Paul S.

This paper reviews issues related to the use of aeroelastic tailoring as a cost-effective, passive means to shape the power curve and reduce loads. Wind turbine blades bend and twist during operation, effectively altering the angle of attack, which in turn affects loads and energy production. There are blades now in use that have significant aeroelastic couplings, either on purpose or because of flexible and light-weight designs. Since aeroelastic effects are almost unavoidable in flexible blade designs, it may be desirable to tailor these effects to the authors advantage. Efforts have been directed at adding flexible devices to a blade, or blade tip, to passively regulate power (or speed) in high winds. It is also possible to build a small amount of desirable twisting into the load response of a blade with proper asymmetric fiber lay up in the blade skin. (Such coupling is akin to distributed {delta}{sub 3} without mechanical hinges.) The tailored twisting can create an aeroelastic effect that has payoff in either better power production or in vibration alleviation, or both. Several research efforts have addressed different parts of this issue. Research and development in the use of aeroelastic tailoring on helicopter rotors is reviewed. Potential energy gains as a function of twist coupling are reviewed. The effects of such coupling on rotor stability have been studied and are presented here. The ability to design in twist coupling with either stretching or bending loads is examined also.

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Two-dimensional Green`s function Poisson solution appropriate for cylindrical-symmetry simulations

Riley, Merle E.

This report describes the numerical procedure used to implement the Green`s function method for solving the Poisson equation in two-dimensional (r,z) cylindrical coordinates. The procedure can determine the solution to a problem with any or all of the applied voltage boundary conditions, dielectric media, floating (insulated) conducting media, dielectric surface charging, and volumetric space charge. The numerical solution is reasonably fast, and the dimension of the linear problem to be solved is that of the number of elements needed to represent the surfaces, not the whole computational volume. The method of solution is useful in the simulation of plasma particle motion in the vicinity of complex surface structures as found in microelectronics plasma processing applications. This report is a stand-alone supplement to the previous Sandia Technical Report SAND98-0537 presenting the two-dimensional Cartesian Poisson solver.

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The surface area modulation downhole telemetry system for measurement while drilling

Ballard, Sanford B.

The need for a reliable, fast, wireless telemetry system in the drilling industry is great but the technical challenge to develop such a system is huge. A downhole wireless telemetry system based on Surface Area Modulation (SAM) has been developed which involves the introduction of an electrically insulated gap near the bottom of an otherwise conductive drillstring. The electrical resistance of this gap can be modulated to alter the electrical characteristics of a circuit involving a surface power supply, the sections of the drillstring above and below the gap, the earth, and a nearby return electrode. These changes alter the current in the circuit, which can be monitored at the surface with an ammeter. Downhole data are encoded and transmitted to the surface as a pattern of current oscillations. In a field test, the SAM system successfully transmitted downhole information from depths of 1,400 ft below the fluid level to the surface at a rate of 110 baud. Electrical insulation on the outside of the simulated drillstring was required to achieve this level of performance. Electrically insulated tubing improved the data transmission rate at a given depth by more than an order of magnitude, and increased the maximum depth from which successful data telemetry could be achieved by more than a factor of two.

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Efficient Monte Carlo probability estimation with finite element response surfaces built from progressive lattice sampling

Romero, Vicente J.

The concept of ``progressive Lattice Sampling`` as a basis for generating successive finite element response surfaces that are increasingly effective in matching actual response functions is investigated here. The goal is optimal response surface generation, which achieves an adequate representation of system behavior over the relevant parameter space of a problem with a minimum of computational and user effort. Such is important in global optimization and in estimation of system probabilistic response, which are both made much more viable by replacing large complex computer models of system behavior by fast running accurate approximations. This paper outlines the methodology for Finite Element/Lattice Sampling (FE/LS) response surface generation and examines the effectiveness of progressively refined FE/LS response surfaces in decoupled Monte Carlo analysis of several model problems. The proposed method is in all cases more efficient (generally orders of magnitude more efficient) than direct Monte Carlo evaluation, with no appreciable loss of accuracy. Thus, when arriving at probabilities or distributions by Monte Carlo, it appears to be more efficient to expend computer model function evaluations on building a FE/LS response surface than to expend them in direct Monte Carlo sampling. Furthermore, the marginal efficiency of the FE/LS decoupled Monte Carlo approach increases as the size of the computer model increases, which is a very favorable property.

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Sub-wavelength diffractive optics

Warren, M.E.

This report represents the completion of a three-year Laboratory-Directed Research and Development (LDRD) program to investigate sub-wavelength surface relief structures fabricated by direct-write e-beam technology as unique and very high-efficiency optical elements. A semiconductor layer with sub-wavelength sized etched openings or features can be considered as a layer with an effective index of refraction determined by the fraction of the surface filled with semiconductor relative to the fraction filled with air or other material. Such as a layer can be used to implement planar gradient-index lenses on a surface. Additionally, the nanometer-scale surface structures have diffractive properties that allow the direct manipulation of polarization and altering of the reflective properties of surfaces. With this technology a single direct-write mask and etch can be used to integrate a wide variety of optical functions into a device surface with high efficiencies; allowing for example, direct integration of polarizing optics into the surface with high efficiencies; allowing for example, direct integration of polarizing optics into the surfaces of devices, forming anti-reflection surfaces or fabricating high-efficiency, high-numerical aperture lenses, including integration inside vertical semiconductor laser cavities.

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High-speed modulation of vertical cavity surface emitting lasers

Hietala, Vincent M.

This report summarizes work on the development of high-speed vertical cavity surface emitting lasers (VCSELs) for multi-gigabit per second optical data communications applications (LDRD case number 3506.010). The program resulted in VCSELs that operate with an electrical bandwidth of 20 GHz along with a simultaneous conversion efficiency (DC to light) of about 20%. To achieve the large electrical bandwidth, conventional VCSELs were appropriately modified to reduce electrical parasitics and adapted for microwave probing for high-speed operation.

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High-G accelerometer for earth-penetrator weapons applications. LDRD final report

Davies, Brady R.

Micromachining technologies, or Micro-Electro-Mechanical Systems (MEMS), enable the develop of low-cost devices capable of sensing motion in a reliable and accurate manner. Sandia has developed a MEMS fabrication process for integrating both the micromechanical structures and microelectronics circuitry of surface micromachined sensors, such as silicon accelerometers, on the same chip. Integration of the micromechanical sensor elements with microelectronics provides substantial performance and reliability advantages for MEMS accelerometers. A design team at Sandia was assembled to develop a micromachined silicon accelerometer capable of surviving and measuring very high accelerations (up to 50,000 times the acceleration due to gravity). The Sandia integrated surface micromachining process was selected for fabrication of the sensor due to the extreme measurement sensitivity potential associated with integrated microelectronics. Very fine measurement sensitivity was required due to the very small accelerometer proof mass (< 200 {times} 10{sup {minus}9} gram) obtainable with this surface micromachining process. The small proof mass corresponded to small sensor deflections which required very sensitive electronics to enable accurate acceleration measurement over a range of 1,000 to 50,000 times the acceleration due to gravity. Several prototype sensors, based on a suspended plate mass configuration, were developed and the details of the design, modeling, fabrication and validation of the device will be presented in this paper. The device was analyzed using both conventional lumped parameter modeling techniques and finite element analysis tools. The device was tested and performed well over its design range (the device was tested over a range of a few thousand G to 46,000 G, where 1 G equals the acceleration due to gravity).

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Flocking small smart machines: An experiment in cooperative, multi-machine control

Klarer, Paul R.

The intent and purpose of this work was to investigate and demonstrate cooperative behavior among a group of mobile robot machines. The specific goal of this work was to build a small swarm of identical machines and control them in such a way as to show a coordinated movement of the group in a flocking manner, similar to that observed in nature. Control of the swarm`s individual members and its overall configuration is available to the human user via a graphic man-machine interface running on a base station control computer. Any robot may be designated as the nominal leader through the interface tool, which then may be commanded to proceed to a particular geographic destination. The remainder of the flock follows the leader by maintaining their relative positions in formation, as specified by the human controller through the interface. The formation`s configuration can be altered manually through an interactive graphic-based tool. An alternative mode of control allows for teleoperation of one robot, with the flock following along as described above.

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An advanced unmanned vehicle for remote applications

Pletta, J.B.

An autonomous mobile robotic capability is critical to developing remote work applications for hazardous environments. A few potential applications include humanitarian demining and ordnance neutralization, extraterrestrial science exploration, and hazardous waste cleanup. The ability of the remote platform to sense and maneuver within its environment is a basic technology requirement which is currently lacking. This enabling technology will open the door for force multiplication and cost effective solutions to remote operations. The ultimate goal of this work is to develop a mobile robotic platform that can identify and avoid local obstacles as it traverses from its current location to a specified destination. This goal directed autonomous navigation scheme uses the Global Positioning System (GPS) to identify the robot`s current coordinates in space and neural network processing of LADAR range images for local obstacle detection and avoidance. The initial year funding provided by this LDRD project has developed a small exterior mobile robotic development platform and a fieldable version of Sandia`s Scannerless Range Imager (SRI) system. The robotic testbed platform is based on the Surveillance And Reconnaissance ground Equipment (SARGE) robotic vehicle design recently developed for the US DoD. Contingent upon follow-on funding, future enhancements will develop neural network processing of the range map data to traverse unstructured exterior terrain while avoiding obstacles. The SRI will provide real-time range images to a neural network for autonomous guidance. Neural network processing of the range map data will allow real-time operation on a Pentium based embedded processor board.

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The role of data analysis in sampling design of environmental monitoring

Shyr, L.J.; Herrera, H.; Haaker, R.

The report is intended to address the need for data analysis in environmental sampling programs. Routine environmental sampling has been conducted at Sandia National Laboratories/New Mexico (SNL/NM) to ensure that site operations have not resulted in undue risk to the public and the environment. Over the years, large amounts of data have been accumulated. The richness of the data should be fully utilized to improve sampling design and prioritize sampling needs for a technically-sound, yet cost-effective sampling design. The report presents a methodology for analyzing environmental monitoring data and demonstrates the application by using SNL`s historical monitoring data. Recommendations for sampling design modification were derived based on the results of the analyses.

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A user`s guide to LUGSAN II. A computer program to calculate and archive lug and sway brace loads for aircraft-carried stores

Dunn, W.N.

LUG and Sway brace ANalysis (LUGSAN) II is an analysis and database computer program that is designed to calculate store lug and sway brace loads for aircraft captive carriage. LUGSAN II combines the rigid body dynamics code, SWAY85, with a Macintosh Hypercard database to function both as an analysis and archival system. This report describes the LUGSAN II application program, which operates on the Macintosh System (Hypercard 2.2 or later) and includes function descriptions, layout examples, and sample sessions. Although this report is primarily a user`s manual, a brief overview of the LUGSAN II computer code is included with suggested resources for programmers.

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Final report on the design and development of a Rolling Float Meter for drilling-fluid outflow measurement

Staller, George E.

Lost circulation, which is the loss of well drilling fluids to the formation while drilling, is a common problem encountered while drilling geothermal wells. The rapid detection of the loss of well drilling fluids is critical to the successful and cost-effective treatment of the wellbore to stop or minimize lost circulation. Sandia National Laboratories has developed an instrument to accurately measure the outflow rate of drilling fluids while drilling. This instrument, the Rolling Float Meter, has been under development at Sandia since 1991 and is now available for utilization by interested industry users. This report documents recent Rolling Float Meter design upgrades resulting from field testing and industry input, the effects of ongoing testing and evaluation both in the laboratory and in the field, and the final design package that is available to transfer this technology to industry users.

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Calculation of electron emission from a tantalum foil irradiated by 100-kV and 50-kV x-rays

Ballard, William P.

Two Monte Carlo programs, XITRAN and XMTRAN, were developed for calculating the emission of electrons from high-Z foils irradiated with x rays. XITRAN follows all individual elastic collisions of electrons with atoms, whereas XMTRAN uses the condensed-random-walk model. Both codes take into account photo-electrons, fluorescence radiation, and Auger electrons. Comparisons are made with an experiment by Dolan at Sandia Laboratories involving the backward and forward emission of electrons from a tantalum foil irradiated by 100-kV and 50-kV x-ray beams. There is good agreement between results from the XITRAN and XMTRAN codes. There emitted per incident x-ray photon, and in regard to the angular distribution of the emerging electrons. In regard to the electron energy spectra, there is fair agreement down to a spectral energy of 20 keV, whereas below 20 keV the calculated spectra lie considerably below the measurements.

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GRAFLAB 2.3 for UNIX - A MATLAB database, plotting, and analysis tool: User`s guide

Dunn, W.N.

This report is a user`s manual for GRAFLAB, which is a new database, analysis, and plotting package that has been written entirely in the MATLAB programming language. GRAFLAB is currently used for data reduction, analysis, and archival. GRAFLAB was written to replace GRAFAID, which is a FORTRAN database, analysis, and plotting package that runs on VAX/VMS.

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Impact failure and fragmentation properties of metals

Kipp, Marlin E.

In the present study we describe the development of an experimental fracture material property test method specific to dynamic fragmentation. Spherical test samples of the metals of interest are subjected to controlled impulsive stress loads by acceleration to high velocities with a light-gas launcher facility and subsequent normal impact on thin plates. Motion, deformation and fragmentation of the test samples are diagnosed with multiple flash radiography methods. The impact plate materials are selected to be transparent to the x-ray method so that only test metal material is imaged. Through a systematic series of such tests both strain-to-failure and fragmentation resistance properties are determined through this experimental method. Fragmentation property data for several steels, copper, aluminum, tantalum and titanium have been obtained to date. Aspects of the dynamic data have been analyzed with computational methods to achieve a better understanding of the processes leading to failure and fragmentation, and to test an existing computational fragmentation model.

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GaAs Photonic Integrated Circuit (PIC) development for high performance communications

Sullivan, Charles T.

Sandia has established a foundational technology in photonic integrated circuits (PICs) based on the (Al,Ga,In)As material system for optical communication, radar control and testing, and network switching applications at the important 1.3{mu}m/1.55{mu}m wavelengths. We investigated the optical, electrooptical, and microwave performance characteristics of the fundamental building-block PIC elements designed to be as simple and process-tolerant as possible, with particular emphasis placed on reducing optical insertion loss. Relatively conventional device array and circuit designs were built using these PIC elements: (1) to establish a baseline performance standard; (2) to assess the impact of epitaxial growth accuracy and uniformity, and of fabrication uniformity and yield; (3) to validate our theoretical and numerical models; and (4) to resolve the optical and microwave packaging issues associated with building fully packaged prototypes. Novel and more complex PIC designs and fabrication processes, viewed as higher payoff but higher risk, were explored in a parallel effort with the intention of meshing those advances into our baseline higher-yield capability as they mature. The application focus targeted the design and fabrication of packaged solitary modulators meeting the requirements of future wideband and high-speed analog and digital data links. Successfully prototyped devices are expected to feed into more complex PICs solving specific problems in high-performance communications, such as optical beamforming networks for phased array antennas.

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Performance assessment in support of compliance certification application for the WIPP project

Jow, H.N.

The Waste Isolation Pilot Plant (WIPP) is being developed by the US Department of Energy for the geologic (deep underground) disposal of transuranic (TRU) waste. A Compliance Certification Application (CCA) of the WIPP (1) for such disposal was submitted to the US Environmental Protection Agency (EPA) in October, 1996, and is currently under review, with a decision anticipated in late 1997. An important component of the CCA is a performance assessment (PA) for the WIPP carried out by Sandia National Laboratories. The final outcome of the PA is a complementary cumulative distribution function (CCDF) for radionuclide releases from the WIPP to the accessible environment and an assessment of the confidence with which this CCDF can be estimated. This paper describes the computational process used to develop the CCDF. The results of uncertainty and sensitivity analysis are also presented.

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Experimental investigation of creep behavior of reactor vessel lower head

Chu, Tze Y.

The objective of the USNRC supported Lower Head Failure (LHF) Experiment Program at Sandia National Laboratories is to experimentally investigate and characterize the failure of the reactor pressure vessel (RPV) lower head due to the thermal and pressure loads of a severe accident. The experimental program is complemented by a modeling program focused on the development of a constitutive formulation for use in standard finite element structure mechanics codes. The problem is of importance because: lower head failure defines the initial conditions of all ex-vessel events; the inability of state-of-the-art models to simulate the result of the TMI-II accident (Stickler, et al. 1993); and TMI-II results suggest the possibility of in-vessel cooling, and creep deformation may be a precursor to water ingression leading to in-vessel cooling.

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Emerging NDE Technology for aging aircraft

Moore, David G.

This paper presents an overview of several emerging nondestructive evaluation technologies that are being employed or considered for use to inspect commercial transport, commuter aircraft and military aircraft. An overview of the Federal Aviation Administration (FAA) Airworthiness Assurance NDI Validation Center (AANC) is described and how AANC teams with industry, universities, and other federal entities to assess these technologies.

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Finite-element/progressive-lattice-sampling response surface methodology and application to benchmark probability quantification problems

Romero, Vicente J.

Optimal response surface construction is being investigated as part of Sandia discretionary (LDRD) research into Analytic Nondeterministic Methods. The goal is to achieve an adequate representation of system behavior over the relevant parameter space of a problem with a minimum of computational and user effort. This is important in global optimization and in estimation of system probabilistic response, which are both made more viable by replacing large complex computer models with fast-running accurate and noiseless approximations. A Finite Element/Lattice Sampling (FE/LS) methodology for constructing progressively refined finite element response surfaces that reuse previous generations of samples is described here. Similar finite element implementations can be extended to N-dimensional problems and/or random fields and applied to other types of structured sampling paradigms, such as classical experimental design and Gauss, Lobatto, and Patterson sampling. Here the FE/LS model is applied in a ``decoupled`` Monte Carlo analysis of two sets of probability quantification test problems. The analytic test problems, spanning a large range of probabilities and very demanding failure region geometries, constitute a good testbed for comparing the performance of various nondeterministic analysis methods. In results here, FE/LS decoupled Monte Carlo analysis required orders of magnitude less computer time than direct Monte Carlo analysis, with no appreciable loss of accuracy. Thus, when arriving at probabilities or distributions by Monte Carlo, it appears to be more efficient to expend computer-model function evaluations on building a FE/LS response surface than to expend them in direct Monte Carlo sampling.

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Criticality Issues with Highly Enriched Fuels in a Repository Environment

Sanchez, Lawrence C.

This paper presents preliminary analysis of a volcanic tuff repository containing a combination of low enrichment commercial spent nuclear fuels (SNF) and DOE-owned SNF packages. These SNFs were analyzed with respect to their criticality risks. Disposal of SNF packages containing significant fissile mass within a geologic repository must comply with current regulations relative to criticality safety during transportation and handling within operational facilities. However, once the repository is closed, the double contingency credits for criticality safety are subject to unremediable degradation, (e.g., water intrusion, continued presence of neutron absorbers in proximity to fissile material, and fissile material reconfiguration). The work presented in this paper focused on two attributes of criticality in a volcanic tuff repository for near-field and far-field scenarios: (1) scenario conditions necessary to have a criticality, and (2) consequences of a nuclear excursion that are components of risk. All criticality consequences are dependent upon eventual water intrusion into the repository and subsequent breach of the disposal package. Key criticality parameters necessary for a critical assembly are: (1) adequate thermal fissile mass, (2) adequate concentration of fissile material, (3) separation of neutron poison from fissile materials, and (4) sufficient neutron moderation (expressed in units of moderator to fissile atom ratios). Key results from this study indicated that the total energies released during a single excursion are minimal (comparable to those released in previous solution accidents), and the maximum frequency of occurrence is bounded by the saturation and temperature recycle times, thus resulting in small criticality risks.

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Integrated separation and optical detection for novel on-chip chemical analysis

Warren, M.E.

This report represents the completion of a two years Laboratory Directed Research and Development (LDRD) program to investigate miniaturized systems for chemical detection and analysis. The future of advanced chemical detection and analysis is in miniature devices that are able to characterize increasingly complex samples, a laboratory on a chip. In this concept, chemical operations used to analyze complicated samples in a chemical laboratory sample handling, species separation, chemical derivitization and detection are incorporated into a miniature device. By using electrokinetic flow, this approach does not require pumps or valves, as fluids in microfabricated channels can be driven by externally applied voltages. This is ideal for sample handling in miniature devices. This project was to develop truly miniature on-chip optical systems based on Vertical Cavity Surface Emitting Lasers (VCSELs) and diffractive optics. These can be built into a complete system that also has on-chip electrokinetic fluid handling and chemical separation in a microfabricated column. The primary goal was the design and fabrication of an on-chip separation column with fluorescence sources and detectors that, using electrokinetic flow, can be used as the basis of an automated chemical analysis system. Secondary goals involved investigation of a dispersed fluorescence module that can be used to extend the versatility of the basic system and on chip, intracavity laser absorption as a high sensitivity detection technique.

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Quality prediction and mistake proofing: An LDRD final report

McDonald, Michael J.

Sandia National Laboratories is responsible for assuring that the US nuclear deterrent remains credible and that the one in a billion disaster of unintended nuclear detonation never occurs. Letting mistake-generated defects into the stockpile would undermine its mission. The current era of shrinking stockpiles is shrinking Sandia`s opportunities to discover and correct mistakes and fine tune processes over long production runs. In response, Sandia has chosen to develop and use a science-based, life cycle systems engineering practices that, in part, require understanding the design to manufacturing issues in enough detail to tune processes and eliminate mistakes before ever making a part. Defect prevention is a key area of concern that currently lacks sufficient theoretical understanding. This report is the result of a scoping study in the application of best-practice quality techniques that could address Sandia`s stockpile mission. The study provides detail on sources and control of mistakes, poka-yoke or mistake-proofing techniques, the Toyota Production system, and design theory in relation to manufacturing quality prediction. Scoping experiments are described and areas for future research are identified.

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Two-dimensional Green`s function Poisson solution appropriate for feature-scale microelectronics simulations

Riley, Merle E.

This report describes the numerical procedure used to implement the Green`s function method for solving the Poisson equation in two-dimensional Cartesian coordinates. The procedure can determine the solution to a problem with any or all of applied voltage boundary conditions, dielectric media, floating (insulated) conducting media, dielectric surface charging, periodic (reflective) boundary conditions, and volumetric space charge. The numerical solution is reasonably fast, and the dimension of the linear problem to be solved is that of the number of elements needed to represent the surfaces, not the whole computational volume. The method of solution is useful in the simulation of plasma particle motion in the vicinity of complex surface structures as found in microelectronics plasma processing applications. A FORTRAN implementation of this procedure is available from the author.

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Micromechanics and homogenization techniques for analyzing the continuum damage of rock salt

Devries, K.L.; Allen, D.H.; Hurtado, L.D.

This paper presents a model for evaluating microcrack development and dilatant behavior of crystalline rocks. The model is developed within the concepts of continuum mechanics, with special emphasis on the development of internal boundaries in the continuum by utilizing fracture mechanics based cohesive zone models. The model is capable of describing the evolution from initial debonding through complete separation and subsequent void growth of an interface. An example problem of a rock salt specimen subjected to a high deviatoric load and low confinement is presented that predicts preferential opening of fractures oriented parallel with the maximum compressive stress axis.

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Diffusion with condensation and evaporation in porous media

Ho, Clifford K.

Vapor phase transport in porous media is important in a number of environmental and industrial processes: soil moisture transport, vapor phase transport in the vadose zone, transport in the vicinity of buried nuclear waste, and industrial processes such as drying. The diffusion of water vapor in a packed bed containing residual liquid is examined experimentally. The objective is to quantify the effect of enhanced vapor diffusion resulting from evaporation/condensation in porous media subjected to a temperature gradient. Isothermal diffusion experiments in free-space were conducted to qualify the experimental apparatus and techniques. For these experiments measured diffusion coefficients are within 3.6% of those reported in the literature for the temperature range from 25 C to 40 C. Isothermal experiments in packed beds of glass beads were used to determine the tortuosity coefficient resulting in {tau} = 0.78 {+-} 0.028, which is also consistent with previously reported results. Nonisothermal experiments in packed beds in which condensation occurs were conducted to examine enhanced vapor diffusion. The interpretation of the results for these experiments is complicated by a gradual, but continuous, build-up of condensate in the packed beds during the course of the experiment. Results indicate diffusion coefficients which increase as a function of saturation resulting in enhancement of the vapor-phase transport by a factor of approximately four compared to a dry porous medium.

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Real time 3D and heterogeneous data fusion

Little, Charles

This project visualizes characterization data in a 3D setting, in real time. Real time in this sense means collecting the data and presenting it before it delays the user, and processing faster than the acquisition systems so no bottlenecks occur. The goals have been to build a volumetric viewer to display 3D data, demonstrate projecting other data, such as images, onto the 3D data, and display both the 3D and projected images as fast as the data became available. The authors have examined several ways to display 3D surface data. The most effective was generating polygonal surface meshes. They have created surface maps form a continuous stream of 3D range data, fused image data onto the geometry, and displayed the data with a standard 3D rendering package. In parallel with this, they have developed a method to project real-time images onto the surface created. A key component is mapping the data on the correct surfaces, which requires a-priori positional information along with accurate calibration of the camera and lens system.

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Chemical solution deposition of SrBi{sub 2}Ta{sub 2}O{sub 9} (SBT) films for non-volatile memory applications

Boyle, Timothy J.

SrBi{sub 2}Ta{sub 2}O{sub 9} (SBT) films have received considerable attention for use as non-volatile memory elements. The authors have developed a process to prepare SBT films with good ferroelectric properties at low temperatures. In this paper, they will present strategies used to optimize the properties of the films including film composition, the nature of the substrate (or bottom electrode) used, and the thermal processing cycle. Under appropriate conditions, {approximately} 1,700 {angstrom} films can be prepared which have a large switchable polarization (2P{sub r} > 10{micro}C/cm{sup 2}), and an operating voltage {le} 2.0 V.

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Results of performance testing the Russian RPV temperature measurement probe used for annealing

Nakos, James T.

This paper provides information on three (3) topics related to temperature measurements in an annealing procedure: (1) results of a series of experiments performed by CNIITMASH of the Russian consortium MOHT on their reactor pressure vessel (RPV) temperature measurement probe, (2) a discussion regarding uncertainties and errors in RPV temperature measurements, and (3) predictions from a thermal model of a spherical RPV temperature measurement probe. MOHT teamed with MPR Associates and was to perform the Annealing Demonstration Project (ADP) on behalf of the US Department of Energy, ESEERCo, EPRI, CRIEPI, Framatome, and Consumers Power Co. at the Midland plant. Experimental results show that the CNIITMASH probe errors are a maximum of about 27 C (49 F) during a 15 C/hr (27 F/hr) heat-up but only about 3 C (5.4 F) (0.6%) during the hold portion at 470 C (878 F). These errors are much smaller than those obtained from a similar series of experiments performed by Sandia National Laboratories (Sandia). The discussion about uncertainties and errors shows that results presented as a temperature difference provides a measure of the probe error. Qualitative agreement is shown between the model predictions, the experimental results of the CNIITMASH probe and the experimental results of a series of similar experiments performed by Sandia.

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Near Net Shape production of metal components using LENS

Schlienger, M.E.

Rapid Prototyping and Near Net Shape manufacturing technologies are the subject of considerable attention and development efforts. At Sandia National Laboratories, one such effort is LENS (Laser Engineered Net Shaping). The LENS process utilizes a stream of powder and a focused Nd YAG laser to build near net shape fully dense metal parts. In this process, a 3-D solid model is sliced, then an X-Y table is rastered under the beam to build each slice. The laser 1 powder head is incremented upward with each slice and the deposition process is controlled via shuttering of the laser. At present, this process is capable of producing fully dense metal parts of iron, nickel and titanium alloys including tool steels and aluminides. Tungsten components have also been produced. A unique aspect of this process is the ability to produce components wherein the composition varies at differing locations in the part. Such compositional variations may be accomplished in either a stepped or graded fashion. In this paper, the details of the process will be described. The deposition mechanism will be characterized and microstructures and their associated properties will be discussed. Examples of parts which have been produced will be shown and issues regarding dimensional control and surface finish will be addressed.

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Chemical detection of buried landmines

Phelan, James M.

Of all the buried landmine identification technologies currently available, sensing the chemical signature from the explosive components found in landmines is the only technique that can classify non-explosive objects from the real threat. In the last two decades, advances in chemical detection methods has brought chemical sensing technology to the foreground as an emerging technological solution. In addition, advances have been made in the understanding of the fundamental transport processes that allow the chemical signature to migrate from the buried source to the ground surface. A systematic evaluation of the transport of the chemical signature from inside the mine into the soil environment, and through the soil to the ground surface is being explored to determine the constraints on the use of chemical sensing technology. This effort reports on the results of simulation modeling using a one-dimensional screening model to evaluate the impacts on the transport of the chemical signature by variation of some of the principal soil transport parameters.

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Physical and mechanical properties of degraded waste surrogate material

Hansen, Francis D.

This paper discusses rock mechanics testing of surrogate materials to provide failure criteria for compacted, degraded nuclear waste. This daunting proposition was approached by first assembling all known parameters such as the initial waste inventory and rock mechanics response of the underground setting after the waste is stored. Conservative assumptions allowing for extensive degradation processes helped quantify the lowest possible strength conditions of the future state of the waste. In the larger conceptual setting, computations involve degraded waste behavior in transient pressure gradients as gas exits the waste horizon into a wellbore. Therefore, a defensible evaluation of tensile strength is paramount for successful analyses and intentionally provided maximal failed volumes. The very conservative approach assumes rampant degradation to define waste surrogate composition. Specimens prepared from derivative degradation product were consolidated into simple geometries for rock mechanics testing. Tensile strength thus derived helped convince a skeptical peer review panel that drilling into the Waste Isolation Pilot Plant (WIPP) would not likely expel appreciable solids via the drill string.

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Evaluation of the capabilities of the Hanford Reservation and Envirocare of Utah for disposal of potentially problematic mixed low-level waste streams

Waters, Robert D.

The US Department of Energy`s (DOE) Mixed Waste Focus Area is developing a program to address and resolve issues associated with final waste form performance in treating and disposing of DOE`s mixed low-level waste (MLLW) inventory. A key issue for the program is identifying MLLW streams that may be problematic for disposal. Previous reports have quantified and qualified the capabilities of fifteen DOE sites for MLLW disposal and provided volume and radionuclide concentration estimates for treated MLLW based on the DOE inventory. Scoping-level analyses indicated that 101 waste streams identified in this report (approximately 6,250 m{sup 3} of the estimated total treated MLLW) had radionuclide concentrations that may make their disposal problematic. The radionuclide concentrations of these waste streams were compared with the waste acceptance criteria (WAC) for a DOE disposal facility at Hanford and for Envirocare`s commercial disposal facility for MLLW in Utah. Of the treated MLLW volume identified as potentially problematic, about 100 m{sup 3} exceeds the WAC for disposal at Hanford, and about 4,500 m{sup 3} exceeds the WAC for disposal at Envirocare. Approximately 7% of DOE`s total MLLW inventory has not been sufficiently characterized to identify a treatment process for the waste and was not included in the analysis. In addition, of the total treated MLLW volume, about 30% was associated with waste streams that did not have radionuclide concentration data and could not be included in the determination of potentially problematic waste streams.

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Simulation of the environmental fate and transport of chemical signatures from buried landmines

Phelan, James M.

The fate and transport of chemical signature molecules that emanate from buried landmines is strongly influenced by physical chemical properties and by environmental conditions of the specific chemical compounds. Published data have been evaluated as the input parameters that are used in the simulation of the fate and transport processes. A one-dimensional model developed for screening agricultural pesticides was modified and used to simulate the appearance of a surface flux above a buried landmine and estimate the subsurface total concentration. The physical chemical properties of TNT cause a majority of the mass released to the soil system to be bound to the solid phase soil particles. The majority of the transport occurs in the liquid phase with diffusion and evaporation driven advection of soil water as the primary mechanisms for the flux to the ground surface. The simulations provided herein should only be used for initial conceptual designs of chemical pre-concentration subsystems or complete detection systems. The physical processes modeled required necessary simplifying assumptions to allow for analytical solutions. Emerging numerical simulation tools will soon be available that should provide more realistic estimates that can be used to predict the success of landmine chemical detection surveys based on knowledge of the chemical and soil properties, and environmental conditions where the mines are buried. Additional measurements of the chemical properties in soils are also needed before a fully predictive approach can be confidently applied.

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Vehicle exhaust gas chemical sensors using acoustic wave resonators

Cernosek, R.W.

Under Sandia`s Laboratory Directed Research and Development (LDRD) program, novel acoustic wave-based sensors were explored for detecting gaseous chemical species in vehicle exhaust streams. The need exists for on-line, real-time monitors to continuously analyze the toxic exhaust gases -- nitrogen oxides (NOx), carbon monoxide (CO), and hydrocarbons (HC) -- for determining catalytic converter efficiency, documenting compliance to emission regulations, and optimizing engine performance through feedback control. In this project, the authors adapted existing acoustic wave chemical sensor technology to the high temperature environment and investigated new robust sensor materials for improving gas detection sensitivity and selectivity. This report describes one new sensor that has potential use as an exhaust stream residual hydrocarbon monitor. The sensor consists of a thickness shear mode (TSM) quartz resonator coated with a thin mesoporous silica layer ion-exchanged with palladium ions. When operated at temperatures above 300 C, the high surface area film catalyzes the combustion of the hydrocarbon vapors in the presence of oxygen. The sensor acts as a calorimeter as the exothermic reaction slightly increases the temperature, stressing the sensor surface, and producing a measurable deviation in the resonator frequency. Sensitivities as high as 0.44 (ppm-{Delta}f) and (ppm-gas) have been measured for propylene gas, with minimum detectable signals of < 50 ppm of propylene at 500 C.

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Development of the SEA Corporation Powergrid{trademark} photovoltaic concentrator

Maish, Alexander B.

This report covers the three phase effort to bring the SEA Corporation`s Powergrid{trademark} from the concept stage to pilot production. The three phases of this contract covered component development, prototype module development, and pilot line production. The Powergrid is a photovoltaic concentrator that generates direct current electricity directly from sunlight using a linear Fresnel lens. Analysis has shown that the Powergrid has the potential to be very low cost in volume production. Before the start of the project, only proof of concept demonstrations of the components had been completed. During the project, SEA Corporation developed a low cost extruded Fresnel lens, a low cost receiver assembly using one sun type cells, a low cost plastic module housing, a single axis tracking system and frame structure, and pilot production equipment and techniques. In addition, an 800 kW/yr pilot production rate was demonstrated and two 40 kW systems were manufactured and installed.

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Renewable generation and storage project industry and laboratory recommendations

Butler, Paul C.

The US Department of Energy Office of Utility Technologies is planning a series of related projects that will seek to improve the integration of renewable energy generation with energy storage in modular systems. The Energy Storage Systems Program and the Photovoltaics Program at Sandia National Laboratories conducted meetings to solicit industry guidance and to create a set of recommendations for the proposed projects. Five possible projects were identified and a three pronged approach was recommended. The recommended approach includes preparing a storage technology handbook, analyzing data from currently fielded systems, and defining future user needs and application requirements.

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Development of laser cutting/welding depth control using laser spectroscopy and open architecture control of a robotic system

McKee, George R.

This project was driven by the need to identify and provide unique, state-of-the-art solutions to the robotic path planning and precision motion execution problems that face automated processes such as welding and cutting using lasers. The initial LDRD proposal was for a full three years program with a schedule that would create a precision robotic platform capable of providing path planning and precision motion execution using sensor and graphical programming technologies as the first year milestone. Milestones for year two were centered in developing and deploying sensor technologies that support welding and cutting. And year three milestones included the integration of any developed sensors onto the robotic platform under software control to achieve autonomous control of laser welding and cutting processes. The work performed was directed at the goal of establishing a precision robotics platform with the capability to integrate graphical programming, CAD model based path planning, and motion execution under real-time sensor based control. This report covers the progress made toward that goal during the one year of funding.

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Development of a cryogenic EOS capability for the Z Pulsed Radiation Source: Goals and accomplishments of FY97 LDRD project

Hanson, D.L.; Johnston, R.R.; Asay, J.R.

Experimental cryogenic capabilities are essential for the study of ICF high-gain target and weapons effects issues involving dynamic materials response at low temperatures. This report describes progress during the period 2/97-11/97 on the FY97 LDRD project ``Cryogenic EOS Capabilities on Pulsed Radiation Sources (Z Pinch)``. The goal of this project is the development of a general purpose cryogenic target system for precision EOS and shock physics measurements at liquid helium temperatures on the Z accelerator Z-pinch pulsed radiation source. Activity during the FY97 LDRD phase of this project has focused on development of a conceptual design for the cryogenic target system based on consideration of physics, operational, and safety issues, design and fabrication of principal system components, construction and instrumentation of a cryogenic test facility for off-line thermal and optical testing at liquid helium temperatures, initial thermal testing of a cryogenic target assembly, and the design of a cryogenic system interface to the Z pulsed radiation source facility. The authors discuss these accomplishments as well as elements of the project that require further work.

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A suitable low-order, eight-node tetrahedral finite element for solids

Key, Samuel W.

To use the all-tetrahedral mesh generation existing today, the authors have explored the creation of a computationally efficient eight-node tetrahedral finite element (a four-node tetrahedral finite element enriched with four mid-face nodal points). The derivation of the element`s gradient operator, studies in obtaining a suitable mass lumping, and the element`s performance in applications are presented. In particular they examine the eight-node tetrahedral finite element`s behavior in longitudinal plane wave propagation, in transverse cylindrical wave propagation, and in simulating Taylor bar impacts. The element samples only constant strain states and, therefore, has 12 hour-glass modes. In this regard it bears similarities to the eight-node, mean-quadrature hexahedral finite element. Comparisons with the results obtained from the mean-quadrature eight-node hexahedral finite element and the four-node tetrahedral finite element are included. Given automatic all-tetrahedral meshing, the eight-node, constant-strain tetrahedral finite element is a suitable replacement for the eight-node hexahedral finite element in those cases where mesh generation requires an inordinate amount of user intervention and direction to obtain acceptable mesh properties.

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An approach to the development and analysis of wind turbine control algorithms

Veers, Paul S.

The objective of this project is to develop the capability of symbolically generating an analytical model of a wind turbine for studies of control systems. This report focuses on a theoretical formulation of the symbolic equations of motion (EOMs) modeler for horizontal axis wind turbines. In addition to the power train dynamics, a generic 7-axis rotor assembly is used as the base model from which the EOMs of various turbine configurations can be derived. A systematic approach to generate the EOMs is presented using d`Alembert`s principle and Lagrangian dynamics. A Matlab M file was implemented to generate the EOMs of a two-bladed, free yaw wind turbine. The EOMs will be compared in the future to those of a similar wind turbine modeled with the YawDyn code for verification. This project was sponsored by Sandia National Laboratories as part of the Adaptive Structures and Control Task. This is the final report of Sandia Contract AS-0985.

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Final report of LDRD project: Electromagnetic impulse radar for detection of underground structures

Loubriel, Guillermo M.

This report provides a summary of the LDRD project titled: Electromagnetic impulse radar for the detection of underground structures. The project met all its milestones even with a tight two year schedule and total funding of $400 k. The goal of the LDRD was to develop and demonstrate a ground penetrating radar (GPR) that is based on high peak power, high repetition rate, and low center frequency impulses. The idea of this LDRD is that a high peak power, high average power radar based on the transmission of short impulses can be utilized effect can be utilized for ground penetrating radar. This direct time-domain system the authors are building seeks to increase penetration depth over conventional systems by using: (1) high peak power, high repetition rate operation that gives high average power, (2) low center frequencies that better penetrate the ground, and (3) short duration impulses that allow for the use of downward looking, low flying platforms that increase the power on target relative to a high flying platform. Specifically, chirped pulses that are a microsecond in duration require (because it is difficult to receive during transmit) platforms above 150 m (and typically 1 km) while this system, theoretically could be at 10 m above the ground. The power on target decays with distance squared so the ability to use low flying platforms is crucial to high penetration. Clutter is minimized by time gating the surface clutter return. Short impulses also allow gating (out) the coupling of the transmit and receive antennas.

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D-D fusion experiments using fast Z pinches

Spielman, Rick B.

The development of high current (I > 10 MA) drivers provides the authors with a new tool for the study of neutron-producing plasmas in the thermal regime. The imploded deuterium mass (or collisionality) increases as I{sup 2} and the ability of the driver to heat the plasma to relevant fusion temperatures improves as the power of the driver increases. Additionally, fast (<100 ns) implosions are more stable to the usual MHD instabilities that plagued the traditional slower implosions. The authors describe experiments in which deuterium gas puffs or CD{sub 2} fiber arrays were imploded in a fast z-pinch configuration on Sandia`s Saturn facility generating up to 3 {times} 10{sup 12} D-D neutrons. These experiments were designed to explore the physics of neutron-generating plasmas in a z-pinch geometry. Specifically, the authors intended to produce neutrons from a nearly thermal plasma where the electrons and ions have a nearly Maxwellian distribution. This is to be clearly differentiated from the more usual D-D beam-target neutrons generated in many dense plasma focus (DPF) devices.

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Industrial ecology Prosperity Game{trademark}

Beck, David F.

Industrial ecology (IE) is an emerging scientific field that views industrial activities and the environment as an interactive whole. The IE approach simultaneously optimizes activities with respect to cost, performance, and environmental impact. Industrial Ecology provides a dynamic systems-based framework that enables management of human activity on a sustainable basis by: minimizing energy and materials usage; insuring acceptable quality of life for people; minimizing the ecological impact of human activity to levels that natural systems can sustain; and maintaining the economic viability of systems for industry, trade and commerce. Industrial ecology applies systems science to industrial systems, defining the system boundary to incorporate the natural world. Its overall goal is to optimize industrial activities within the constraints imposed by ecological viability, globally and locally. In this context, Industrial systems applies not just to private sector manufacturing and services but also to government operations, including provision of infrastructure. Sandia conducted its seventeenth Prosperity Game{trademark} on May 23--25, 1997, at the Hyatt Dulles Hotel in Herndon, Virginia. The primary sponsors of the event were Sandia National Laboratories and Los Alamos National Laboratory, who were interested in using the format of a Prosperity Game to address some of the issues surrounding Industrial Ecology. Honorary game sponsors were: The National Science Foundation; the Committee on Environmental Improvement, American Chemical Society; the Industrial and Engineering Chemistry Division, American Chemical Society; the US EPA--The Smart Growth Network, Office of Policy Development; and the US DOE-Center of Excellence for Sustainable Development.

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Transformation of filter transmission data for f-number and chief ray angle

Rienstra, Jeffrey L.

This paper describes a method for transforming measured optical and infrared filter data for use with optical systems of arbitrary f-number and angle of incidence. Although it is generally desirable to have normal incidence at the filter (i.e., collimated light where an optical filter is used), other system design considerations may take precedence. In the case of a multispectral sensor under development at Sandia National Laboratories, system constraints require optical filter placement very near the focal plane. The light rays incident on the filters are therefore converging as determined by the system f-number while the chief ray of each ray bundle varies with focal plane position. To analyze the system`s spectral response at different points on the focal plane, a method was devised to transform the filter vendor`s measured data to account for the optical system design. The key to the transformation is the determination of weighting factors and shift factors for each angle of incidence making up a ray bundle. A computer worksheet was developed using a popular mathematical software package which performs this transformation for 75 key points on the focal plane.

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Software attribute visualization for high integrity software

Pollock, Guylaine M.

This report documents a prototype tool developed to investigate the use of visualization and virtual reality technologies for improving software surety confidence. The tool is utilized within the execution phase of the software life cycle. It provides a capability to monitor an executing program against prespecified requirements constraints provided in a program written in the requirements specification language SAGE. The resulting Software Attribute Visual Analysis Tool (SAVAnT) also provides a technique to assess the completeness of a software specification.

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Development of a biaxial test facility for structural evaluation of aircraft fuselage panels

Roach, D.

The number of commercial airframes exceeding twenty years of service continues to grow. An unavoidable by-product of aircraft use is that crack and corrosion flaws develop throughout the aircraft`s skin and substructure elements. Economic barriers to the purchase of new aircraft have created an aging aircraft fleet and placed even greater demands on efficient and safe repair methods. Composite doublers, or repair patches, provide an innovative repair technique which can enhance the way aircraft are maintained. Instead of riveting multiple steel or aluminum plates to facilitate an aircraft repair, it is now possible to bond a single Boron-Epoxy composite doubler to the damaged structure. The composite doubler repair process produces both engineering and economic benefits. The FAA`s Airworthiness Assurance Center at Sandia National Labs completed a project to introduce composite doubler repair technology to the commercial aircraft industry. This paper focuses on a specialized structural test facility which was developed to evaluate the performance of composite doublers on actual aircraft structure. The facility can subject an aircraft fuselage section to a combined load environment of pressure (hoop stress) and axial, or longitudinal, stress. The tests simulate maximum cabin pressure loads and use a computerized feedback system to maintain the proper ratio between hoop and axial loads. Through the use of this full-scale test facility it was possible to: (1) assess general composite doubler response in representative flight load scenarios, and (2) verify the design and analysis approaches as applied to an L-1011 door corner repair.

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Space charge limited degradation of bipolar oxides at low electric-fields

Fleetwood, D.M.

Radiation-induced degradation of many types of bipolar transistors and circuits is more severe following low dose rate exposure than following high dose rate exposure. Since microelectronic devices in space are generally subjected to low dose rate irradiation, this complicates the hardness assurance testing of linear circuits and can lead to an overestimation of device lifetime in space. Previous work examining the physical mechanisms responsible for this dose rate effect has focused primarily on oxide trapped charge. Reduced net positive oxide trapped charge densities at high dose rates and zero bias have been attributed to space charge effects from slowly transporting holes trapped metastably at O vacancy complexes. Decreasing the dose rate or increasing the irradiation temperature leads to an increase in net positive oxide trapped charge near the Si-SiO{sub 2} interface by reducing these space charge effects. In this work, concentrations of hydrogen transport through two types of bipolar oxides are estimated from dopant passivation measurements in MOS capacitors. For unbiased irradiations, hydrogen passivation of substrate acceptors is greatly reduced at high dose rates compared to that at low dose rates or elevated temperatures. Consistent with other widely accepted models, it is argued that fewer interface traps are formed by high dose rate irradiation under zero bias, because fewer H{sup +} ions can drift to the Si-SiO{sub 2} interface and react with trap precursors. Similar to hole transport in these oxides, drift of the H{sup +} ions is inhibited at high dose rates by space charge accumulated in the oxide bulk.

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A basic parallel sparse eigensolver for structural dynamics

Day, David M.

In this work the basic Finite Element Tearing and Interconnecting (FETI) linear system solver and the PARPACK eigensolver are combined to compute the smallest modes of symmetric generalized eigenvalue problems that arise from structures modeled primarily by solid finite elements. Problems with over one million unknowns are solved. A comprehensive and relatively self-contained description of the FETI method is presented.

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Field testing results for the strategic petroleum reserve pipeline corrosion control program

Buchheit, R.G.; Maestas, L.M.; Hinkebein, T.E.

Results of two studies conducted as part of the Strategic Petroleum Reserve (SPR) Pipeline Corrosion Control Program are reported. These studies focused on evaluation of rotary-applied concrete materials for internal pipeline protection against the erosive and corrosive effects of flowing brine. The study also included evaluation of liners applied by hand on pipe pieces that cannot be lined by rotary methods. Such pipe pieces include tees, elbows and flanged pipe sections. Results are reported from a corrosion survey of 17 different liner formulations tested at the-Big-Rill SPR Site. Testing consisted of electrochemical corrosion rate measurements made on lined pipe sections exposed, in a test manifold, to flowing SPR generated fluids. Testing also involved cumulative immersion exposure where samples were exposed to static site-generated brine for increasing periods of time. Samples were returned to the laboratory for various diagnostic analyses. Results of this study showed that standard calcium silicate concrete (API RP10E) and a rotary calcium aluminate concrete formulation were excellent performers. Hand-lined pipe pieces did not provide as much corrosion protection. The focus of the second part of the study was on further evaluation of the calcium silicate, calcium aluminate and hand-applied liners in actual SPR equipment and service. It was a further objective to assess the practicality of electrochemical impedance spectroscopy (EIS) for field corrosion monitoring of concrete lined pipe compared to the more well-known linear polarization technique. This study showed that concrete linings reduced the corrosion rate for bare steel from 10 to 15 mils per year to 1 mil per year or less. Again, the hand-applied liners did not provide as much corrosion protection as the rotary-applied liners. The EIS technique was found to be robust for field corrosion measurements. Mechanistic and kinetic corrosion rate data were reliably obtained.

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Selective dehydrogenation of propane over novel catalytic materials

Sault, Allen G.

The conversion of small alkanes into alkenes represents an important chemical processing area; ethylene and propylene are the two most important organic chemicals manufactured in the U.S. These chemicals are currently manufactured by steam cracking of ethane and propane, an extremely energy intensive, nonselective process. The development of catalytic technologies (e.g., selective dehydrogenation) that can be used to produce ethylene and propylene from ethane and propane with greater selectivity and lower energy consumption than steam cracking will have a major impact on the chemical processing industry. This report details a study of two novel catalytic materials for the selective dehydrogenation of propane: Cr supported on hydrous titanium oxide ion-exchangers, and Pt nanoparticles encapsulated in silica and alumina aerogel and xerogel matrices.

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Department 1824 Job Card System: A new web-based business tool

Brangan, J.R.

The Analytical Chemistry Department uses a system of job cards to control and monitor the work through the organization. In the past, many different systems have been developed to allow each laboratory to monitor their individual work and report data. Unfortunately, these systems were separate and unique which caused difficulty in ascertaining any overall picture of the Department`s workload. To overcome these shortcomings, a new Job Card System was developed on Lotus Notes/Domino{trademark} for tracking the work through the laboratory. This application is groupware/database software and is located on the Sandia Intranet which allows users of any type of computer running a network browser to access the system. Security is provided through the use of logons and passwords for users who must add and/or modify information on the system. Customers may view the jobs in process by entering the system as an anonymous user. An overall view of the work in the department can be obtained by selecting from a variety of on screen reports. This enables the analysts, customers, customer contacts, and the Department Manager to quickly evaluate the work in process, the resources required, and the availability of equipment. On-line approval of the work and e-mail messaging of completed jobs has been provided to streamline the review and approval cycle. This paper provides a guide for the use of the Job Card System and information on maintenance of the system.

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Nondestructive inspection assessment of eddy current and electrochemical analysis to separate inconel and stainless steel alloys

Moore, David G.

This report presents a nondestructive inspection assessment of eddy current and electrochemical analysis to separate inconel alloys from stainless steel alloys as well as an evaluation of cleaning techniques to remove a thermal oxide layer on aircraft exhaust components. The results of this assessment are presented in terms of how effective each technique classifies a known exhaust material. Results indicate that either inspection technique can separate inconel and stainless steel alloys. Based on the experiments conducted, the electrochemical spot test is the optimum for use by airframe and powerplant mechanics. A spot test procedure is proposed for incorporation into the Federal Aviation Administration Advisory Circular 65-9A Airframe & Powerplant Mechanic - General Handbook. 3 refs., 70 figs., 7 tabs.

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An efficient method for calculating RMS von Mises stress in a random vibration environment

Segalman, Daniel J.

An efficient method is presented for calculation of RMS von Mises stresses from stress component transfer functions and the Fourier representation of random input forces. An efficient implementation of the method calculates the RMS stresses directly from the linear stress and displacement modes. The key relation presented is one suggested in past literature, but does not appear to have been previously exploited in this manner.

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A user`s guide to LHS: Sandia`s Latin Hypercube Sampling Software

Wyss, Gregory D.

This document is a reference guide for LHS, Sandia`s Latin Hypercube Sampling Software. This software has been developed to generate either Latin hypercube or random multivariate samples. The Latin hypercube technique employs a constrained sampling scheme, whereas random sampling corresponds to a simple Monte Carlo technique. The present program replaces the previous Latin hypercube sampling program developed at Sandia National Laboratories (SAND83-2365). This manual covers the theory behind stratified sampling as well as use of the LHS code both with the Windows graphical user interface and in the stand-alone mode.

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Sensor-fusion-based biometric identity verification

Bouchard, Ann M.

Future generation automated human biometric identification and verification will require multiple features/sensors together with internal and external information sources to achieve high performance, accuracy, and reliability in uncontrolled environments. The primary objective of the proposed research is to develop a theoretical and practical basis for identifying and verifying people using standoff biometric features that can be obtained with minimal inconvenience during the verification process. The basic problem involves selecting sensors and discovering features that provide sufficient information to reliably verify a person`s identity under the uncertainties caused by measurement errors and tactics of uncooperative subjects. A system was developed for discovering hand, face, ear, and voice features and fusing them to verify the identity of people. The system obtains its robustness and reliability by fusing many coarse and easily measured features into a near minimal probability of error decision algorithm.

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Sensing and compressing 3-D models

Carlson, Jeffrey J.

The goal of this research project was to create a passive and robust computer vision system for producing 3-D computer models of arbitrary scenes. Although the authors were unsuccessful in achieving the overall goal, several components of this research have shown significant potential. Of particular interest is the application of parametric eigenspace methods for planar pose measurement of partially occluded objects in gray-level images. The techniques presented provide a simple, accurate, and robust solution to the planar pose measurement problem. In addition, the representational efficiency of eigenspace methods used with gray-level features were successfully extended to binary features, which are less sensitive to illumination changes. The results of this research are presented in two papers that were written during the course of this project. The papers are included in sections 2 and 3. The first section of this report summarizes the 3-D modeling efforts.

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Demonstration of real-time monitoring of a photolithographic exposure process using chemical ionization mass spectrometry

Mowry, Curtis D.

Silicon wafers are coated with photoresist and exposed to ultraviolet (UV) light in a laboratory to simulate typical conditions expected in an actual semiconductor manufacturing process tool. Air is drawn through the exposure chamber and analyzed using chemical ionization mass spectrometry (CI/MS). Species that evaporate or outgas from the wafer are thus detected. The purpose of such analyses is to determine the potential of CI/MS as a real-time process monitoring tool. Results demonstrate that CI/MS can remotely detect the products evolved before, during, and after wafer UV exposure; and that the quantity and type of products vary with the photoresist coated on the wafer. Such monitoring could provide semiconductor manufacturers benefits in quality control and process analysis. Tool and photoresist manufacturers could also realize benefits from this measurement technique with respect to new tool, method, or photoresist development. The benefits realized can lead to improved device yields and reduced product and development costs.

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Mechanical diode: Comparing numerical and experimental characterizations

Sagartz, M.J.

In this introductory work, joint compliance is studied in both a numerical and experimental setting. A simple bolted interface is used as the test article and compliance is measured for the joint in both compression and in tension. This simple interface is shown to exhibit a strong non-linearity near the transition from compression to tension (or vice-versa). Modeling issues pertaining to numerically solving for the compliance are addressed. It is shown that the model predictions, in spite of convergence being very sensitive to numerical artifacts of the interface model, are in good agreement with experimentally measured strains and joint compliances. The joint behavior is a mechanical analogy to a diode, i.e., in compression, the joint is very stiff, acting almost as a rigid link, while in tension the joint is relatively soft, acting as a spring.

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Molecular dynamics simulations of microscale fluid transport

Wong, C.C.; Lopez, A.R.; Stevens, M.J.; Plimpton, S.J.

Recent advances in micro-science and technology, like Micro-Electro-Mechanical Systems (MEMS), have generated a group of unique liquid flow problems that involve characteristic length scales of a Micron. Also, in manufacturing processes such as coatings, current continuum models are unable to predict microscale physical phenomena that appear in these non-equilibrium systems. It is suspected that in these systems, molecular-level processes can control the interfacial energy and viscoelastic properties at the liquid/solid boundary. A massively parallel molecular dynamics (MD) code has been developed to better understand microscale transport mechanisms, fluid-structure interactions, and scale effects in micro-domains. Specifically, this MD code has been used to analyze liquid channel flow problems for a variety of channel widths, e.g. 0.005-0.05 microns. This report presents results from MD simulations of Poiseuille flow and Couette flow problems and addresses both scaling and modeling issues. For Poiseuille flow, the numerical predictions are compared with existing data to investigate the variation of the friction factor with channel width. For Couette flow, the numerical predictions are used to determine the degree of slip at the liquid/solid boundary. Finally, the results also indicate that shear direction with respect to the wall lattice orientation can be very important. Simulation results of microscale Couette flow and microscale Poiseuille flow for two different surface structures and two different shear directions will be presented.

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Development of explosive event scale model testing capability at Sandia`s large scale centrifuge facility

Davie, Neil T.

Geotechnical structures such as underground bunkers, tunnels, and building foundations are subjected to stress fields produced by the gravity load on the structure and/or any overlying strata. These stress fields may be reproduced on a scaled model of the structure by proportionally increasing the gravity field through the use of a centrifuge. This technology can then be used to assess the vulnerability of various geotechnical structures to explosive loading. Applications of this technology include assessing the effectiveness of earth penetrating weapons, evaluating the vulnerability of various structures, counter-terrorism, and model validation. This document describes the development of expertise in scale model explosive testing on geotechnical structures using Sandia`s large scale centrifuge facility. This study focused on buried structures such as hardened storage bunkers or tunnels. Data from this study was used to evaluate the predictive capabilities of existing hydrocodes and structural dynamics codes developed at Sandia National Laboratories (such as Pronto/SPH, Pronto/CTH, and ALEGRA). 7 refs., 50 figs., 8 tabs.

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Vectors a Fortran 90 module for 3-dimensional vector and dyadic arithmetic

Brock, Billy C.

A major advance contained in the new Fortran 90 language standard is the ability to define new data types and the operators associated with them. Writing computer code to implement computations with real and complex three-dimensional vectors and dyadics is greatly simplified if the equations can be implemented directly, without the need to code the vector arithmetic explicitly. The Fortran 90 module described here defines new data types for real and complex 3-dimensional vectors and dyadics, along with the common operations needed to work with these objects. Routines to allow convenient initialization and output of the new types are also included. In keeping with the philosophy of data abstraction, the details of the implementation of the data types are maintained private, and the functions and operators are made generic to simplify the combining of real, complex, single- and double-precision vectors and dyadics.

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Spatial and temporal resolution of fluid flows: LDRD final report

Tieszen, Sheldon R.

This report describes a Laboratory Directed Research and Development (LDRD) activity to develop a diagnostic technique for simultaneous temporal and spatial resolution of fluid flows. The goal is to obtain two orders of magnitude resolution in two spatial dimensions and time simultaneously. The approach used in this study is to scale up Particle Image Velocimetry (PIV) and Planar Laser Induced Fluorescence (PLIF) to acquire meter-size images at up to 200 frames/sec. Experiments were conducted in buoyant, fully turbulent, non-reacting and reacting plumes with a base diameter of one meter. The PIV results were successful in the ambient gas for all flows, and in the plume for non-reacting helium and reacting methane, but not reacting hydrogen. No PIV was obtained in the hot combustion product region as the seed particles chosen vaporized. Weak signals prevented PLIF in the helium. However, in reacting methane flows, PLIF images speculated to be from Poly-Aromatic-Hydrocarbons were obtained which mark the flame sheets. The results were unexpected and very insightful. A natural fluorescence from the seed particle vapor was also noted in the hydrogen tests.

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Final report on LDRD project: Low-cost Pd-catalyzed metallization technology for rapid prototyping of electronic substrates and devices

Chen, Ken S.

A low-cost, thermally-activated, palladium-catalyzed metallization process was developed for rapid prototyping of polymeric electronic substrates and devices. The process was successfully applied in producing adhesiveless copper/polyimide laminates with high peel strengths and thick copper coating; copper/polyimide laminates are widely used in fabricating interconnects such as printed wiring boards (PWBs) and flexible circuits. Also successfully metallized using this low-cost metallization process were: (1) scaled-down models of radar-and-communication antenna and waveguide; (2) scaled-down model of pulsed-power-accelerator electrode; (3) three-dimensional micro-porous, open-cell vitreous carbon foams. Moreover, additive patterned metallization was successfully achieved by selectively printing or plotting the catalyst ink only on areas where metallization is desired, and by uniform thermal activation. Additive patterned metallization eliminates the time-consuming, costly and environmentally-unfriendly etching process that is routinely carried out in conventional subtractive patterned metallization. A metallization process via ultraviolet (UV) irradiation activation was also demonstrated. In this process palladium-catalyst solution is first uniformly coated onto the substrate. A masking pattern is used to cover the areas where metallization is not wanted. UV irradiation is applied uniformly to activate the palladium catalyst and to cure the polymer carrier in areas that are not covered by the mask. Metal is then deposited by electroless plating only or by a combination of electroless and electrolytic plating. This UV-activation technique is particularly useful in additive fine-line patterned metallization. Lastly, computer models for electrolytic and electroless plating processes were developed to provide guidance in plating-process design.

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CONTAIN assessment of the NUPEC mixing experiments. Supplement 1

Stamps, D.W.

In the original report (Reference 1), to which this report is a supplement, the results of CONTAIN code calculations were presented for five thermal-hydraulic experiments performed in the NUPEC 1/4-scale model containment, including the International Standard Problem ISP-35. In the original report, calculated helium concentrations were presented per NUPEC`s specifications for ISP-35. In contrast, this supplemental report presents the helium concentrations on a conventional dry basis, which is physically consistent with the gas chromatography data. These conventionally defined dry helium concentrations are compared with the previously reported results and are found to exhibit trends that are more consistent with measured data. While agreement between the predicted results and data is substantially improved in general for the M-8-1 experiment using these helium concentrations as opposed to the ISP-35 specifications, general improvement in agreement is not observed in all cases.

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Integration of US Department of Energy contractor installations for the purpose of optimizing treatment, storage, and disposal of low-level radioactive waste (LLW)

Lucas, Michael D.

The US Department of Energy (DOE) manages a multibillion dollar environmental management (EM) program. In June 1996, the Assistant Secretary of Energy for EM issued a memorandum with guidance and a vision for a ten year planning process for the EM Program. The purpose of this process, which became known as the Accelerated Cleanup: Focus on 2006, is to make step changes within the DOE complex regarding the approach for making meaningful environmental cleanup progress. To augment the process, Assistant Secretary requested the site contractors to engage in an effort to identify and evaluate integration alternatives for EM waste stream treatment, storage, and disposal (TSD) that would parallel the 2006 Plan. In October 1996, ten DOE contractor installations began the task of identifying alternative opportunities for low level radioactive waste (LLW). Cost effective, efficient solutions were necessary to meet all requirements associated with storing, characterizing, treating, packaging, transporting, and disposing of LLW while protecting the workers` health and safety, and minimizing impacts to the environment. To develop these solutions, a systems engineering approach was used to establish the baseline requirements, to develop alternatives, and to evaluate the alternatives. Key assumptions were that unique disposal capabilities exist within the DOE that must be maintained; private sector disposal capability for some LLW may not continue to exist into the foreseeable future; and decisions made by the LLW Team must be made on a system or complex wide basis to fully realize the potential cost and schedule benefits. This integration effort promoted more accurate waste volume estimates and forecasts; enhanced recognition of existing treatment, storage, and disposal capabilities and capacities; and improved identification of cost savings across the complex.

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Integration and evaluation of a position sensor with continuous read-out for use with the Environmental Measurement-While-Drilling Gamma Ray Spectrometer system

Williams, Cecelia V.

The Environmental Measurement-While-Drilling-Gamma Ray Spectrometer (EMWD-GRS) system represents an innovative blend of new and existing technology that provides real-time environmental and drill bit data during drilling operations. The EMWD-GRS technology was demonstrated at Savannah River Site (SRS) F-Area Retention Basin. The EMWD-GRS technology demonstration consisted of continuously monitoring for gamma-radiation-producing contamination while drilling two horizontal boreholes below the backfilled waste retention basin. These boreholes passed near previously sampled locations where concentrations of contaminant levels of cesium had been measured. Contaminant levels continuously recorded by the EMWD-GRS system during drilling were compared to contaminant levels previously determined through quantitative laboratory analysis of soil samples. The results show general agreement between the soil sampling and EMWD-GRS techniques for Cs-137. The EMWD-GRS system has been improved by the integration of an orientation sensor package for position sensing (PS) (EMWD-GRS/PS). This added feature gives the capability of calculating position, which is tied directly to EMWD-GRS sensor data obtained while drilling. The EMWD-GRS/PS system is described and the results of the field tests are presented.

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Natural attenuation of metals and radionuclides -- An overview of the Sandia/DOE approach

Waters, Robert D.

Sandia National Laboratories is developing guidelines that outline the technical basis for relying on natural attenuation for the remediation of metals and radionuclide-contaminated soils and groundwaters at US Department of Energy (DOE) sites for those specific cases where natural processes are effective at ameliorating soil and groundwater toxicity. Remediation by monitored natural attenuation (MNA) requires a clear identification of the specific reaction(s) by which contaminant levels are made less available as well as considerable long-term monitoring. Central to MNA is the development of a conceptual model describing the biogeochemical behavior of contaminant(s) in the subsurface. The conceptual model will be used to make testable predictions of contaminant availability over time. In many cases, comparison between this prediction and field measurements will provide the test of whether MNA is to be implemented. As a result, development of the conceptual model should guide site characterization activities as well as long-term monitoring.

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New trends in the commercial IC industry and the impact on defense electronics

Dellin, Theodore A.

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Dynamic visualization techniques for high consequence software

Pollock, Guylaine M.

This report documents a prototype tool developed to investigate the use of visualization and virtual reality technologies for improving software surety confidence. The tool is utilized within the execution phase of the software life cycle. It provides a capability to monitor an executing program against prespecified requirements constraints provided in a program written in the requirements specification language SAGE. The resulting Software Attribute Visual Analysis Tool (SAVAnT) also provides a technique to assess the completeness of a software specification. The prototype tool is described along with the requirements constraint language after a brief literature review is presented. Examples of how the tool can be used are also presented. In conclusion, the most significant advantage of this tool is to provide a first step in evaluating specification completeness, and to provide a more productive method for program comprehension and debugging. The expected payoff is increased software surety confidence, increased program comprehension, and reduced development and debugging time.

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The impact of tungsten long rod penetrators into water filled targets

Hertel, Eugene S.

Twelve experiments were conducted to determine the effect of water filled targets on the penetration of tungsten long rods in terms of their residual mass and integrity. CTH hydrocode calculations were performed for each of the experiments to ensure that the erosion and breakup of the tungsten projectiles could be accurately reproduced. The CTH hydrocode predictions correlation well with the experimental results in most cases. Only 8% of the variance is unexplained. The slip interface between the rod and water was approximated in one of two ways: (1) using the CTH BLINT option in 2-D or (2) using a standard Eulerian mixed cells treatment. Results indicate that a 3-D BLINT algorithm is critical to predicting rod residual lengths. The authors were unable to reproduce rod fracture that occurred in every experiment where the water column exceeded 25 cm in length. The authors feel that this is due to a change in rod material properties during penetration, and continue to investigate the issue.

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Benchmarking the SPHINX and CTH shock physics codes for three problems in ballistics

Hertel, Eugene S.

The CTH Eulerian hydrocode, and the SPHINX smooth particle hydrodynamics (SPH) code were used to model a shock tube, two long rod penetrations into semi-infinite steel targets, and a long rod penetration into a spaced plate array. The results were then compared to experimental data. Both SPHINX and CTH modeled the one-dimensional shock tube problem well. Both codes did a reasonable job in modeling the outcome of the axisymmetric rod impact problem. Neither code correctly reproduced the depth of penetration in both experiments. In the 3-D problem, both codes reasonably replicated the penetration of the rod through the first plate. After this, however, the predictions of both codes began to diverge from the results seen in the experiment. In terms of computer resources, the run times are problem dependent, and are discussed in the text.

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Crack detection on HC-130H aircraft using low frequency eddy current

Moore, David G.

An eddy current inspection method was developed at the Federal Aviation Administration`s Airworthiness Assurance NDI Validation Center (AANC) to easily and rapidly detect subsurface fatigue cracks in the wheel well fairing on the US Coast Guard (USCG) HC-130H aircraft caused by fatigue. The inspection procedure locates cracks as small as 10.2 millimeters in length at 2.54 mm below the skin surface at raised fastener sites. The test procedure developed baseline three USCG aircraft. Inspection results on the three aircraft reveals good correlation with results made during subsequent structural disassembly.

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Dielectrics for GaN based MIS-diodes

Baca, A.G.

GaN MIS diodes were demonstrated utilizing AlN and Ga{sub 2}O{sub 3}(Gd{sub 2}O{sub 3}) as insulators. A 345 {angstrom} of AlN was grown on the MOCVD grown n-GaN in a MOMBE system using trimethylamine alane as Al precursor and nitrogen generated from a wavemat ECR N2 plasma. For the Ga{sub 2}O{sub 3}(Gd{sub 2}O{sub 3}) growth, a multi MBE chamber was used and a 195 {angstrom} oxide is E-beam evaporated from a single crystal source of Ga{sub 5}Gd{sub 3}O{sub 12}. The forward breakdown voltage of AlN and Ga{sub 2}O{sub 3}(Gd{sub 2}O{sub 3}) diodes are 5V and 6V, respectively, which are significantly improved from {approximately} 1.2 V of schottky contact. From the C-V measurements, both kinds of diodes showed good charge modulation from accumulation to depletion at different frequencies. The insulator GaN interface roughness and the thickness of the insulator were measured with x-ray reflectivity.

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Industrial Partnership Prosperity Game{trademark}

Boyack, Kevin W.

Prosperity Games TM are an outgrowth and adaptation move/countermove and seminar War Games. Prosperity Games TM are simulations that explore complex issues in a variety of areas including economics, politics, sociology, environment, education, and research. These issues can be examined from a variety of perspectives ranging from a global, macroeconomic and geopolitical viewpoint down to the details of customer/supplier/market interactions in specific industries. All Prosperity Games TM are unique in that both the game format and the player contributions vary from game to game. This report documents the Industry Partnership Prosperity Game sponsored by the Technology Partnerships and Commercialization Center at Sandia National Laboratories. Players came from the Sandia line organizations, the Sandia business development and technology partnerships organizations, the US Department of Energy, academia, and industry The primary objectives of this game were to: explore ways to increase industry partnerships to meet long-term Sandia goals; improve Sandia business development and marketing strategies and tactics; improve the process by which Sandia develops long-term strategic alliances. The game actions and recommendations of these players provided valuable insights as to what Sandia can do to meet these objectives.

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Optimization strategies for complex engineering applications

Eldred, Michael S.

LDRD research activities have focused on increasing the robustness and efficiency of optimization studies for computationally complex engineering problems. Engineering applications can be characterized by extreme computational expense, lack of gradient information, discrete parameters, non-converging simulations, and nonsmooth, multimodal, and discontinuous response variations. Guided by these challenges, the LDRD research activities have developed application-specific techniques, fundamental optimization algorithms, multilevel hybrid and sequential approximate optimization strategies, parallel processing approaches, and automatic differentiation and adjoint augmentation methods. This report surveys these activities and summarizes the key findings and recommendations.

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Lessons learned from early microelectronics production at Sandia National Laboratories

Weaver, H.T.

During the 1980s Sandia designed, developed, fabricated, tested, and delivered hundreds of thousands of radiation hardened Integrated Circuits (IC) for use in weapons and satellites. Initially, Sandia carried out all phases, design through delivery, so that development of next generation ICs and production of current generation circuits were carried out simultaneously. All this changed in the mid-eighties when an outside contractor was brought in to produce ICs that Sandia developed, in effect creating a crisp separation between development and production. This partnership had a severe impact on operations, but its more damaging effect was the degradation of Sandia`s microelectronics capabilities. This report outlines microelectronics development and production in the early eighties and summarizes the impact of changing to a separate contractor for production. This record suggests that low volume production be best accomplished within the development organization.

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Free form fabrication of thermoplastic composites

Kaufman, Stephen G.

This report describes the results of composites fabrication research sponsored by the Laboratory Directed Research and Development (LDRD) program at Sandia National Laboratories. They have developed, prototyped, and demonstrated the feasibility of a novel robotic technique for rapid fabrication of composite structures. Its chief innovation is that, unlike all other available fabrication methods, it does not require a mold. Instead, the structure is built patch by patch, using a rapidly reconfigurable forming surface, and a robot to position the evolving part. Both of these components are programmable, so only the control software needs to be changed to produce a new shape. Hence it should be possible to automatically program the system to produce a shape directly from an electronic model of it. It is therefore likely that the method will enable faster and less expensive fabrication of composites.

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Understanding the system in risk assessment

Craft, R.

In the assessment of a system, understanding the system is central. Even so, most of the current literature takes a narrow view of understanding, making only the catalog of system ``assets`` explicit, while maintaining the balance of the analyst`s understanding inside the analyst`s head. This can lead to problems with non-repeatability and incompleteness of assessment results. This paper introduces the notion of using explicit system models to document the analyst`s understanding of the system and shows that, from these models, standard assessment products, such as fault trees and event trees, can be automatically derived. This paper also presents five ``views`` of a system that can be used to document the analyst`s understanding of the system. These views go well beyond the standard instruction to identify the system`s assets to show that a much richer understanding of the system can be required for effective assessment.

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Planning and scheduling for agile manufacturers: The Pantex Process Model

Kjeldgaard, Edwin A.

Effective use of resources that are shared among multiple products or processes is critical for agile manufacturing. This paper describes the development and implementation of a computerized model to support production planning in a complex manufacturing system at the Pantex Plant, a US Department of Energy facility. The model integrates two different production processes (nuclear weapon disposal and stockpile evaluation) that use common facilities and personnel at the plant. The two production processes are characteristic of flow-shop and job shop operations. The model reflects the interactions of scheduling constraints, material flow constraints, and the availability of required technicians and facilities. Operational results show significant productivity increases from use of the model.

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A one-dimensional analysis of sol-gel film-coating drying: Pore evolution, network shrinkage and stress development

Chen, Ken S.

Highly porous sol-gel films have potential applications as electrical and thermal insulators, catalyst supports, sensors, and membranes for gas separations. Pore dimensions in these sol-gel films are usually small e.g., on the order of tens of nanometers or less. Their successful fabrications, however, greatly depend on the fundamental understanding of mechanisms that underlie the phenomena of pore evolution, network shrinkage, and stress development since the final microstructure of a solid gel film is strongly affected by composition of its starting sol and its processing conditions. This report documents a simplified one-dimensional analysis of drying a solidifying sol-gel thin film coating supported by an impermeable solid substrate. Portions of this work were presented at the 1994 Annual Joint Meeting of the New Mexico Section of the American Ceramic Society and Materials Research Society in Albuquerque. The authors considered the solid/liquid two phase coexistent regime during the drying solidifying process in which solvent is removed continuously via evaporation, the solid phase grows significantly in mechanical strength, and pore space shrinks appreciably. From overall and differential mass balances and a force balance at equilibrium, coupled with empirical correlations of solid phase modulus and permeability to strain or deformation, the authors followed the evolution of pore space, solid phase elastic stress, and liquid phase hydrodynamic pressure; they also determined their respective values at equilibrium. By assuming microscopic pore shape models, they estimated and compared the predicted mean pore radii. Their simplified one-dimensional analysis shows that the final mean pore radius is controlled by four parameters: pore-liquid surface tension, solid phase modulus, mean pore radius, and porosity at the initial stress-free state. The one-dimensional model can be employed to guide process design and optimization in sol-gel film fabrications.

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Comparison of three work of adhesion measurements

Emerson, John A.

Practical work of adhesion measurements are being studied for several types of polymer/metal combinations in order to obtain a better understanding of the adhesive failure mechanisms for systems containing encapsulated and bonded components. The primary question is whether studies of model systems can be extended to systems of technological interest. The authors report on their first attempts to obtain the work of adhesion between a PDMS polymer and stainless steel. The work of adhesion measurements were made using three techniques -- contact angle, adhesive fracture energy at low deformation rates and JKR. Previous work by Whitesides` group show a good correlation between JKR and contact angle measurements for PDMS. Their initial work focused on duplicating the PDMS measurements of Chaudury. In addition, in this paper the authors extend the work of adhesion measurement to third technique -- interfacial failure energy. The ability to determine the reversible work of adhesion for practical adhesive joints allows understanding of several issues that control adhesion: surface preparation, nature of the interphase region, and bond durability.

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Precursor ion damage and single event gate rupture in thin oxides

Sexton, Frederick W.

Gate oxide electric fields are expected to increase to greater than 5 MV/cm as feature size approaches 0.1 micrometers in advanced integrated circuit (IC) technologies. Work by Johnston, et al. raised the concern that single event gate rupture (SEGR) may limit the scaling of advanced ICs for space applications. SEGR has also been observed in field programmable gate arrays, which rely on thin dielectrics for electrical programming at very high electric fields. The focus of this effort is to further explore the mechanisms for SEGR in thin gate oxides. The authors examine the characteristics of heavy ion induced breakdown and compare them to ion induced damage in thin gate oxides. Further, the authors study the impact of precursor damage in oxides on SEGR threshold. Finally, they compare thermal and nitrided oxides to see if SEGR is improved by incorporating nitrogen in the oxide.

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Overview of the joint US/Russia surety program in the Sandia National Laboratories Cooperative Measures Program

Smith, R.E.

Sandia National Laboratories has initiated many joint research and development projects with the two premier Russian nuclear laboratories, VNIIEF and VNIITF, (historically known as Arzamas-16 and Chelyabinsk-70) in a wide spectrum of areas. One of the areas in which critical dialogue and technical exchange is continuing to take place is in the realm of system surety. Activities primarily include either safety or security methodology development, processes, accident environment analyses and testing, accident data-bases, assessments, and product design. Furthermore, a continuing dialog has been established between the organizations with regard to developing a better understanding of how risk is perceived and analyzed in Russia versus that in the US. The result of such efforts could reduce the risk of systems to incur accidents or incidents resulting in high consequences to the public. The purpose of this paper is to provide a current overview of the Sandia surety program and its various initiatives with the Russian institutes, with an emphasis on the program scope and rationale. The historical scope of projects will be indicated. A few specific projects will be discussed, along with results to date. The extension of the joint surety initiatives to other government and industry organizations will be described. This will include the current status of a joint Sandia/VNIIEF initiative to establish an International Surety Center for Energy Intensive and High Consequence Systems and Infrastructures.

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Modeling macroscopic response of random composites

Aidun, John B.

Preliminary work is presented on an effort to generate synthetic constitutive data for random composite materials. The long-ranged goal is to use the overall response determined from finite element simulations of representative volumes (RV) of the heterogeneous material to construct a homogenized constitutive model. A simple composite of a matrix containing polydispersed spheres was chosen as the first configuration to simulate. Here the accuracy of the numerical simulation tools is tested by determining effective elastic constants of the ordered elastic composite in which equal-sized spheres are arranged in each of three cubic lattice configurations. The resulting anisotropic effective elastic constant values agree with theoretical results to better than 10%, with typical agreement being better than 4%.

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Boundary element method applied to a gas-fired pin-fin-enhanced heat pipe

Andraka, Charles E.

The thermal conduction of a portion of an enhanced surface heat exchanger for a gas fired heat pipe solar receiver was modeled using the boundary element and finite element methods (BEM and FEM) to determine the effect of weld fillet size on performance of a stud welded pin fin. A process that could be utilized by others for designing the surface mesh on an object of interest, performing a conversion from the mesh into the input format utilized by the BEM code, obtaining output on the surface of the object, and displaying visual results was developed. It was determined that the weld fillet on the pin fin significantly enhanced the heat performance, improving the operating margin of the heat exchanger. The performance of the BEM program on the pin fin was measured (as computational time) and used as a performance comparison with the FEM model. Given similar surface element densities, the BEM method took longer to get a solution than the FEM method. The FEM method creates a sparse matrix that scales in storage and computation as the number of nodes (N), whereas the BEM method scales as N{sup 2} in storage and N{sup 3} in computation.

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Transition to management -- A personal perspective

Williams, Janet L.

This paper explores one woman`s journey through her recent promotion into management, and will identify key factors that helped prepare and position her to be ready to exercise leadership through a formal management role. It discusses assessment of qualifications and skills, acquisition of needed skills, the influence of luck and timing, and the use of mentors and delegation as survival skills to get through the transition period and become fully functional as a manager. It also includes insights into sensitive issues such as how to relate to former peers, how to gain credibility as the junior member of the management team, and how to juggle family responsibilities with increased time commitments at work. It emphasizes the importance of acknowledging the help the authors receive in reaching their own career goals and offering the same kind of help and support to those in the early stages of their careers.

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Massively parallel linear stability analysis with P_ARPACK for 3D fluid flow modeled with MPSalsa

Lecture Notes in Computer Science (including subseries Lecture Notes in Artificial Intelligence and Lecture Notes in Bioinformatics)

Lehoucq, Richard B.

We are interested in the stability of three-dimensional fluid flows to small disturbances. One computational approach is to solve a sequence of large sparse generalized eigenvalue problems for the leading modes that arise from discretizating the differential equations modeling the flow. The modes of interest are the eigenvalues of largest real part and their associated eigenvectors. We discuss our work to develop an efficient and reliable eigensolver for use by the massively parallel simulation code MPSalsa. MPSalsa allows simulation of complex 3D fluid flow, heat transfer, and mass transfer with detailed bulk fluid and surface chemical reaction kinetics.

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Development of high-Z plasma facing components for ITER

Fusion Technology

Watson, Robert D.

During the ITER EDA (Engineering Design Activity), the US Home Team developed improved methods for fabricating tungsten armored plasma facing components. Thermo-mechanical modeling indicated the desirability of using `brush-like' structures (clusters of small filaments or rods) as a means of reducing thermal stresses. The commercial availability of tungsten welding electrode rods (1.6 mm and 3.2 mm diameter) significantly reduced the raw material costs. Three approaches were developed: (1) Cu is plasma sprayed to the W brushes followed by diffusion bonding or e-beam welding the copper backing to the CuCrZr heat sink, (2) Molten Cu is cast directly on the tips of the W brushes followed by the diffusion bonding step, and (3) W rods are sputter-coated with a bonding aid and are directly bonded to the CuCrZr heat sink using HIP or vacuum hot pressing. High heat flux testing was performed up to 18 MW/m2 without damage to two small-scale divertor mockups.

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Determination of modal residues and residual flexibility for time-domain system realization

Journal of Guidance, Control, and Dynamics

Alvin, Kenneth F.

A linear least-squares procedure for the determination of modal residues using time-domain system realization theory is presented. The present procedure is intended to complement existing techniques for time-domain system identification and is shown to be theoretically equivalent to residue determination in realization algorithms such as the eigensystem realization algorithm and Q-Markov covariance equivalent realization method. However, isolating the optimal residue estimation problem from the general realization problem affords several alternative strategies as compared to standard realization algorithms for structural dynamics identification. Primary among these are alternative techniques for handling data sets with large numbers of sensors using small numbers of reference point responses and the inclusion of terms that accurately model the effects of residual flexibility. The accuracy and efficiency of the present realization theory-based procedure is demonstrated for both simulated and experimental data.

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Re-START: The second operational test of the String Thermionic Assembly Research Testbed

Wyant, Francis J.

The second operational test of the String Thermionic Assembly Research Testbed -- Re-START -- was carried out from June 9 to June 14, 1997. This test series was designed to help qualify and validate the designs and test methods proposed for the Integrated Solar Upper Stage (ISUS) power converters for use during critical evaluations of the complete ISUS bimodal system during the Engine Ground Demonstration (EGD). The test article consisted of eight ISUS prototype thermionic converter diodes electrically connected in series.

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Results 91301–91400 of 96,771
Results 91301–91400 of 96,771