Publications

Butyl rubber, unfortunately, has pronounced nonlinear viscoelastic behavior, which may be modelled by a separable KBKZ formalism. While these effects seem to have minimal impact on accelerated sealing force measurements, they do severely impact compression set tests. Therefore, a new test is suggested for evaluating field-return o-rings which is free from such confounding effects.

This report describes the results of a Sandia-funded laboratory-directed research and development project titled {open_quotes}Integrated and Robust Security Infrastructure{close_quotes} (IRSI). IRSI was to provide a broad range of commercial-grade security services to any software application. IRSI has two primary goals: application transparency and manageable public key infrastructure. IRSI must provide its security services to any application without the need to modify the application to invoke the security services. Public key mechanisms are well suited for a network with many end users and systems. There are many issues that make it difficult to deploy and manage a public key infrastructure. IRSI addressed some of these issues to create a more manageable public key infrastructure.

This report summarizes measured performance of residential geothermal heat pumps (GHP`s) that were installed in family housing units at Ft. Hood, Texas and at Selfridge Air National Guard base in Michigan. These units were built as part of a joint Department of Defense/Department of Energy program to evaluate the energy savings potential of GHP`s installed at military facilities. At the Ft. Hood site, the GHP performance was compared to conventional forced air electric air conditioning and natural gas heating. At Selfridge, the homes under test were originally equipped with electric baseboard heat and no air conditioning. Installation of the GHP systems at both sites was straightforward but more problems and costs were incurred at Selfridge because of the need to install ductwork in the homes. The GHP`s at both sites produced impressive energy savings. These savings approached 40% for most of the homes tested. The low cost of energy on these bases relative to the incremental cost of the GHP conversions precludes rapid payback of the GHP`s from energy savings alone. Estimates based on simple payback (no inflation and no interest on capital) indicated payback times from 15 to 20 years at both sites. These payback times may be reduced by considering the additional savings possible due to reduced maintenance costs. Results are summarized in terms of 15 minute, hourly, monthly, and annual performance parameters. The results indicate that all the systems were working properly but several design shortcomings were identified. Recommendations are made for improvements in future installations at both sites.

Results from simulations of the impact and penetration of tungsten alloy rods into thick rolled armor plates are presented. The calculations were performed with the CTH and ALEGRA computer codes using the DOE massively parallel TFLOPS computer co-developed by Sandia National Laboratory and Intel Corporation. Comparisons with experimental results are presented. Agreement of the two codes with each other and with the empirical results for penetration channel depth and radius is very close. Other shock physics and penetration features are also compared to simulation results.

Analytical models of wind turbine blades have many uncertainties, particularly with composite construction where material properties and cross-sectional dimension may not be known or precisely controllable. In this paper the authors demonstrate how modal testing can be used to estimate important material parameters and to update and improve a finite-element (FE) model of a prototype wind turbine blade. An example of prototype blade is used here to demonstrate how model parameters can be identified. The starting point is an FE model of the blade, using best estimates for the material constants. Frequencies of the lowest fourteen modes are used as the basis for comparisons between model predictions and test data. Natural frequencies and mode shapes calculated with the FE model are used in an optimal test design code to select instrumentation (accelerometer) and excitation locations that capture all the desired mode shapes. The FE model is also used to calculate sensitivities of the modal frequencies to each of the uncertain material parameters. These parameters are estimated, or updated, using a weighted least-squares technique to minimize the difference between test frequencies and predicted results. Updated material properties are determined for axial, transverse, and shear moduli in two separate regions of the blade cross section: in the central box, and in the leading and trailing panels. Static FE analyses are then conducted with the updated material parameters to determine changes in effective beam stiffness and buckling loads.

Natural attenuation is increasingly applied to remediate contaminated soils and ground waters. Roughly 25% of Superfund groundwater remedies in 1995 involved some type of monitored natural attenuation, compared to almost none 5 years ago. Remediation by natural attenuation (RNA) requires clear evidence that contaminant levels are decreasing sufficiently over time, a defensible explanation of the attenuation mechanism, long-term monitoring, and a contingency plan at the very least. Although the primary focus of implementation has to date been the biodegradation of organic contaminants, there is a wealth of scientific evidence that natural processes reduce the bioavailability of contaminant metals and radionuclides. Natural attenuation of metals and radionuclides is likely to revolve around sorption, solubility, biologic uptake and dilution controls over contaminant availability. Some of these processes can be applied to actively remediate sites. Others, such as phytoremediation, are likely to be ineffective. RNA of metals and radionuclides is likely to require specialized site characterization to construct contaminant and site-specific conceptual models of contaminant behavior. Ideally, conceptual models should be refined such that contaminant attenuation can be confidently predicted into the future. The technical approach to RNA of metals and radionuclides is explored here.

During July--November, 1995, Sandia National Laboratories, in cooperation with CE Exploration, drilled a 5,360 feet exploratory slimhole (3.895 inch diameter) in the Newberry Known Geothermal Resource Area (KGRA) near Bend, Oregon. This well was part of Sandia`s program to evaluate slimholes as a geothermal exploration tool. During and after drilling the authors performed numerous temperature logs, and at the completion of drilling attempted to perform injection tests. In addition to these measurements, the well`s data set includes: over 4,000 feet of continuous core (with detailed log); daily drilling reports from Sandia and from drilling contractor personnel; daily drilling fluid record; and comparative data from other wells drilled in the Newberry KGRA. This report contains: (1) a narrative account of the drilling and testing, (2) a description of equipment used, (3) a brief geologic description of the formation drilled, (4) a summary and preliminary interpretation of the data, and (5) recommendations for future work.

Corrosion is a leading material degradation mode observed in many military systems. This report contains a description of a small project that was performed to allow some of the important electrochemical aspects of two distinct and potentially relevant degradation modes to be better understood: environmentally assisted cracking (EAC) of aluminum alloys and corrosion in moist salt. Two specific and respective tasks were completed: (A) the characterization of the effect of aluminum microstructural variability on its susceptibility to EAC, and (B) the development of experimental and analytical techniques that can be used to identify the factors and processes that influence the corrosivity of moist salt mixtures. The resultant information constitutes part of the basis needed to ultimately predict component reliability and/or possibly to identify techniques that could be used to control corrosion in critical components. In Task A, a physical model and related understanding for the relevant degradation processes were formulated. The primary result from Task B included the identification and qualitative validation of a methodology for determining the corrosivity of salt mixtures. A detailed compilation of the results obtained from each of these two diverse tasks is presented separately in the body of this report.

This report describes the creation of three-dimensional numerical models of selected rock-matrix properties for the region of the potential high-level nuclear waste repository site at Yucca Mountain, which is located in southern Nevada. The models have been generated for a majority of the unsaturated and shallow saturated zone within an area referred to within the Yucca Mountain Site Characterization project as the site area. They comprise a number of material properties of importance both to detailed process-level modeling activities and to more summary-style performance assessment modeling. The material properties within these models are both spatially variable (heterogeneous) and spatially correlated, as the rocks are understood from data obtained from site-characterization drill holes widely scattered across the site area.

This report summarizes the investigation and evaluation of several {open_quotes}compact{close_quotes} drill rigs which could be used for drilling geothermal production wells. Use of these smaller rigs would save money by reducing mobilization costs, fuel consumption, crew sizes, and environmental impact. Advantages and disadvantages of currently-manufactured rigs are identified, and desirable characteristics for the {open_quotes}ideal{close_quotes} compact rig are defined. The report includes a detailed cost estimate of a specific rig, and an evaluation of the cost/benefit ratio of using this rig. Industry contacts for further information are given.

During the DOE Onsite Review in August 1996, Sandia`s Executive Vice President formally proposed combining Sandia`s Institutional Plan and Operating Plan, and their associated processes. The Assistant Secretary for Defense Programs subsequently approved a pilot plan to do so. This pilot plan is intended to comply with one of our new strategic objectives (see section 3.7), which entails creating an infrastructure that is a competitive advantage for our strategic missions. Therefore, Sandia`s planning organization integrated the information in the two plans and collected the data with a unified call. These data can not be combined in multiple ways, depending on customer requirements. Recently, executive management revamped Sandia`s Strategic Plan by creating eight new strategic objectives: four primary whats and four supporting hows. The new strategic objectives are set forth in chapters 3 through 5 of this document. The four primary objectives cover nuclear weapons responsibilities, nonproliferation and materials control, energy and critical infrastructures, and emerging national security threats. The major programmatic initiatives in chapter 7 are grouped accordingly. However, the programmatic descriptions in chapter 6 and the associated funding tables in chapter 9 continue to be presented by DOE Budget and Reporting Code, as in previous Sandia institutional plans. As an aid to the reader, the four primary strategic objectives in chapter 3 are cross-referenced to the program information in chapter 6.

This paper describes the method by which Sandia National Laboratories has deployed information technology to the line organizations and to the desktop as part of the integrated information services organization under the direction of the Chief Information officer. This deployment has been done by the Computer Support Unit (CSU) Department. The CSU approach is based on the principle of providing local customer service with a corporate perspective. Success required an approach that was both customer compelled at times and market or corporate focused in most cases. Above all, a complete solution was required that included a comprehensive method of technology choices and development, process development, technology implementation, and support. It is the authors hope that this information will be useful in the development of a customer-focused business strategy for information technology deployment and support. Descriptions of current status reflect the status as of May 1997.

Significant progress has been made over the past year in understanding the chemistry and processing challenges associated with {sup 99}Mo production using Cintichem type targets. Targets fabricated at Los Alamos National Laboratory have been successfully irradiated in fuel element locations at the Annular Core Research Reactor (ACRR) and processed at the Sandia Hot Cell Facility. The next goal for the project is to remove the central cavity experiment tube from the reactor core, allowing for the irradiation of up to 37 targets. After the in-core work is complete, the reactor will be capable of producing significant quantities of {sup 99}Mo.

The Monitoring Systems Technology Center (MSTC) at Sandia National Laboratories has recently upgraded its Satellite Parts Inventory Forms 3.0 application to Developer/2000 for the web. This involved changing from a character based Forms 3.0 system on an HP-UX 9000 database and forms server to a GUI forms 4.5 web- based system on Windows NT 4.0 Forms Serve. The need to migrate the MSTC Satellite Parts Inventory System to a newer supported software environment, that was easy to access and use, and was year 2000 compliant, drove the migration from forms 3.0. This paper will examine the steps of this successful migration to a web environment in detail. The MSTC Satellite Parts Inventory System includes a parts inventory application for inventory management of flight qualified electronic parts. This application tracks parts from receipt to fabrication, including manufacturer information such as lot and date, and quantities data such as lot totals, quantity on order and reorder levels. The system keeps a current count of parts that are used in kitting modules/assemblies for fabrication, does automated picks of the oldest parts, and allows suggested parts to be pulled or put back in stock and the required part pulled in place of the system suggested part. The system also flags and notifies component engineers of parts that fall below a certain level and includes traceability of parts to module record of assembly (ROA), module ROA repairs, drawings definition, CAD queue scheduling, purchase requisition records, and module action and document management.

The ability to model the packing of polymers in melts and blends is important in many polymer applications. One significant application is the development of new polymer blends. It would be exceedingly helpful to the materials chemist if molecular modeling could be employed to predict the thermodynamics and phase behavior of hypothetical polymer alloys before embarking on a time consuming and expensive synthesis program. The well known Flory-Huggins theory has been remarkably successful in describing many aspects of polymer mixing from a qualitative point of view. This theory is known, however, to suffer from several deficiencies which can be traceable to the fact that: (1) it is a lattice model requiring both monomer components to have the same volume; and (2) a mean field or random mixing approximation is made which effectively ignores chain connectivity. Because of these limitations the Flory-Huggins theory does not include packing effects and cannot be used to make quantitative molecular engineering calculations. Recently Curro and Schweizer developed a new approach for treating polymer liquids and mixtures which the authors call PRISM theory. This is an extension to polymers of the Reference Interaction Site Model (RISM Theory) developed by Chandler and Andersen to describe the statistical mechanics of small molecule liquids. The PRISM theory is a continuous space description of a polymer liquid, which includes chain connectivity and nonrandom mixing effects in a computationally tractable manner. The primary output from PRISM calculations is the average structure or packing of the amorphous liquid given by the radial distribution function denoted as g(r). This radial distribution function is employed to deduce thermodynamic or structural properties of interest. Here, the authors describe the theoretical approach and demonstrate its application to polyethylene, isotactic polypropylene, syndiotactic polypropylene, and polyisobutylene liquids and blends.

The magnitudes of accident dose risks calculated by the RADTRAN code depend directly on the time span between an accidental release and evacuation of the affected area surrounding potential radionuclide releases. In a previous study of truck and rail transportation accidents, and other incidents requiring evacuations, a lognormal distribution of evacuation times (time span from decision to evacuate until complete) was developed, which provided a better model for this parameter than the practice of using a highly conservative value of 24 hours. However, the distribution did not account for time required for responders to arrive on the scene, to evaluate the hazards to surrounding population and to initiate an evacuation. Data from US Department of Transportation (DOT) accident statistics have been collected and their distribution functions determined. The separate distribution functions were combined into a single, comprehensive distribution which may be sampled to supply values of the RADTRAN input parameter, EVACUATION. A sample RADTRAN calculation illustrating the effect on risks of using the distribution versus the original (24 hour), conservative point-estimate are also presented.

In the transport of radioactive material (RAM), e.g., spent nuclear fuel (SNF), stakeholders are generally most concerned about risks in high population density areas along transportation routes because of the perceived high consequences of potential accidents. The most significant portions of a transcontinental route and an alternative examined previously were evaluated again using population density data derived from US Census Block data. This method of characterizing population that adjoins route segments offers improved resolution of population density variations, especially in high population density areas along typical transport routes. Calculated incident free doses and accident dose risks for these routes, and the rural, suburban and urban segments are presented for comparison of their relative magnitudes. The results indicate that modification of this route to avoid major metropolitan areas through use of non-Interstate highways increases total risk yet does not eliminate a relatively small urban component of the accident dose risk. This conclusion is not altered by improved resolution of route segments adjoining high density populations.

Severe ship accidents and the probability of radioactive material release from spent reactor fuel casks were investigated previously. Other forms of RAM, e.g., plutonium oxide powder, may be shipped in large numbers of packagings rather than in one to a few casks. These smaller, more numerous packagings are typically placed in ISO containers for ease of handling, and several ISO containers may be placed in one of several holds of a cargo ship. In such cases, the size of a radioactive release resulting from a severe collision with another ship is determined not by the likelihood of compromising a single, robust package but by the probability that a certain fraction of 10`s or 100`s of individual packagings is compromised. The previous analysis involved a statistical estimation of the frequency of accidents which would result in damage to a cask located in one of seven cargo holds in a collision with another ship. The results were obtained in the form of probabilities (frequencies) of accidents of increasing severity and of release fractions for each level of severity. This paper describes an extension of the same general method in which the multiple packages are assumed to be compacted by an intruding ship`s bow until there is no free space in the hold. At such a point, the remaining energy of the colliding ship is assumed to be dissipated by progressively crushing the RAM packagings and the probability of a particular fraction of package failures is estimated by adaptation of the statistical method used previously. The parameters of a common, well characterized packaging, the 6M with 2R inner containment vessel, were employed as an illustrative example of this analysis method. However, the method is readily applicable to other packagings for which crush strengths have been measured or can be estimated with satisfactory confidence.

Even prior to the beginning of the nuclear age, the packaging and transportation of nuclear materials was a prime national concern. Nuclear materials such as uranium and plutonium had to be transported safely (and secretly) to the Manhattan Engineer District Laboratory in Los Alamos, New Mexico. The subsequent post war use of nuclear power for the generation of electricity and accelerated weapons development programs resulted in radioactive waste byproducts, such as spent fuel and plutonium, that were stored on site at utilities and federal weapons sites. While projected repositories for long term storage of radioactive waste are being planned, both low and high level radioactive materials on occasion must be moved safely. Movement to interim storage and, for low level waste, repository sites, is accomplished by a combination of truck, rail, ship, and air. The US Department of Energy (DOE) directs transportation activities including cask development technology for use in single or multimodal (a combination of land, water, and air) transport. In 1978, Sandia National Laboratories was selected as the lead contractor for basic transportation technology. This report is divided into the following topics: (1) early research and development (1936--1978); (2) radioactive material package test (1975--1977); (3) the SNL Transportation Technology Center; (4) TRUPACT-II; (5) beneficial uses of shipping system casks; (6) C-141B drop tests; (7) MIDAS; (8) MOSAIK; (9) SEARAM; (10) PATRAM; and (11) a chronology of transportation activities.

The Radioactive Materials Incident Report (RMIR) database was developed in 1981 at the Transportation Technology Center of Sandia National Laboratories to support its research and development activities for the US Department of Energy (DOE). This database contains information about radioactive materials transportation incidents that have occurred in the US since 1971. These data were drawn from the US Department of Transportation`s (DOT) Hazardous Materials Incident Report system, from Nuclear Regulatory Commission (NRC) files, and from various agencies including state radiological control offices. Support for the RMIR data base is funded by the National Transportation Program (EM-70) of the US Department of Energy. Transportation events in RMIR are classified in one of the following ways: as a transportation accident, as a handling accident, or as a reported incident. This presentation will provide definitions for these classifications and give examples of each. The primary objective of this presentation is to provide information on nuclear materials transportation accident incident events in the US for the period 1971--1997. Among the areas to be examined are: transportation accidents by mode, package response during accidents and an examination of accidents where release of contents has occurred.

Little guidance has been provided by the DOE for developing appropriate Operational Safety Requirements (OSR) for non-nuclear facility safety documents. For a period of time, Chapter 2 of DOE/AL Supplemental Order 5481.lB provided format guidance for non-reactor nuclear facility OSRs when this supplemental order applied to both nuclear and non-nuclear facilities. Thus, DOE Albuquerque Operations Office personnel still want to see non-nuclear facility OSRs in accordance with the supplemental order (i.e., in terms of Safety Limits, Limiting Conditions for Operation, and Administrative Controls). Furthermore, they want to see a clear correlation between the OSRs and the results of a facility safety analysis. This paper demonstrates how OSRs can be rather simply derived from the results of a risk assessment performed using the ``binning`` methodology of SAND95-0320.

An original computational technique to generate close-to-equilibrium dense polymeric structures is proposed. Diffusion of small gases are studied on the equilibrated structures using massively parallel molecular dynamics simulations running on the Intel Teraflops (9216 Pentium Pro processors) and Intel Paragon(1840 processors). Compared to the current state-of-the-art equilibration methods this new technique appears to be faster by some orders of magnitude.The main advantage of the technique is that one can circumvent the bottlenecks in configuration space that inhibit relaxation in molecular dynamics simulations. The technique is based on the fact that tetravalent atoms (such as carbon and silicon) fit in the center of a regular tetrahedron and that regular tetrahedrons can be used to mesh the three-dimensional space. Thus, the problem of polymer equilibration described by continuous equations in molecular dynamics is reduced to a discrete problem where solutions are approximated by simple algorithms. Practical modeling applications include the constructing of butyl rubber and ethylene-propylene-dimer-monomer (EPDM) models for oxygen and water diffusion calculations. Butyl and EPDM are used in O-ring systems and serve as sealing joints in many manufactured objects. Diffusion coefficients of small gases have been measured experimentally on both polymeric systems, and in general the diffusion coefficients in EPDM are an order of magnitude larger than in butyl. In order to better understand the diffusion phenomena, 10, 000 atoms models were generated and equilibrated for butyl and EPDM. The models were submitted to a massively parallel molecular dynamics simulation to monitor the trajectories of the diffusing species.

Since the discovery of piezoresistivity in silicon in the mid 1950s. silicon-based pressure sensors have been widely produced. Micromachining technology has greatly benefited from the success of the integrated circuit industry, borrowing materials, processes, and toolsets. Because of this, microelectromechanical systems (MEMS) are now poised to capture large segments of existing sensor markets and to catalyse the development of new markets. Given the emerging importance of MEMS, it is instructive to review the history of micromachined pressure sensors, and to examine new developments in the field. Pressure sensors will be the locus of this paper, starting from metal diaphragm sensors with bonded silicon strain gauges, and moving to present developments of surface-micromachined, optical, resonant, and smart pressure sensors. Considerations for diaphragm design will be discussed in detail, as well as additional considerations for capacitive and piezoresistive devices. Results from surface-micromachined pressure sensors developed by the authors will be presented. Finally, advantages of micromachined sensors will be discussed.

Non-linear electromagnetic inversion schemes have been developed to produce 2D and 3D images of subsurface conductivity structure from electromagnetic geophysical data. The solutions are obtained by successive linearized model updates where full forward modeling is employed at each iteration to compute model sensitivities and predicted data. Regularization is applied to the problem to provide stability. The use of the inversion is demonstrated on a data set collected with the Apex Parametrics MaxMin I-8S over a section of conductive waste at the Idaho National Laboratory`s Cold Test Pit. The out-of -phase data are of very good quality while the in-phase are rather noisy due to slight mispositioning errors. A resolution study on synthetic data indicates that the error present in the in-phase data causes images of far lower resolution with more artifacts than if the in-phase and out-of-phase components are of similar quality. Better resolution images result if the data are weighted proportional to frequency; this gives each frequency equal importance. The loss of resolution due to poor quality in-phase data is demonstrated in a 3D inversion of the MaxMin data which shows both artifacts forming outside of the area known to contain the buried waste, as well as an inability to resolve depths.

This paper discusses criteria for selecting analytical support tools for manufacturing engineering in the early phases of product development, and the lessons learned at Sandia National Laboratories in selecting and applying these tools. The IPPD (Integrated Product and Process Design) process requires manufacturing process developers to be involved earlier than ever before in product development. Operating in an IPPD environment, Sandia`s manufacturing engineers were required to develop early estimates of the cost and performance of manufacturing plans. In early pre-production, there are very little actual data on manufacturing processes and almost no detailed data on the performance of various manufacturing process steps. The manufacturing engineer needs the capability to analyze various manufacturing process flows over a large set of assumptions involving capacity, resource requirements (equipment, labor, material, utilities,...), yields, product designs, etc. If the manufacturing process involves many process steps, or if there are multiple products in a single manufacturing area that share resources, or there are multiple part starts resulting in merged flow for final assembly, then this analysis capability must somehow be mechanized. This situation led them to look to modeling and simulation tools for a solution. Example analyses of manufacturing issues for two product sets in the early phases of product development are presented.

The electrical and chemical properties of insulators produced by codeposition of siloxane compounds or TEOS with oxygen in a focused ion beam (FIB) system were investigated. Metal-insulator-metal capacitor structures were fabricated and tested. Specifically, leakage current and breakdown voltage were measured and used to calculate the effective resistance and breakdown field. Capacitance measurements were performed on a subset of the structures. It was found that the siloxane-based FIB-insulators had superior electrical properties to those based on TEOS. Microbeam Rutherford backscattering spectrometry analysis and Fourier transform infrared spectroscopy were used to characterize the films and to help understand the differences in electrical behavior as a function of gas chemistry and deposition conditions. Finally, a comparison is made between the results presented here, previous results for FIB-deposited insulators, and typical thermally-grown gate oxides and interlevel dielectric SiO{sub 2} insulators.

In late 1993, the authors` mission expanded from engineering design to also encompass production of neutron generator devices. They completed a gap analysis of the tools needed to support this emerging production assignment and, as a result, introduced a Product Data Management (PDM) system. This implementation includes basic PDM features, Web access, interfaces to the production floor and suppliers, and other utilities. They carefully strategized, piloted and assessed the integration of the PDM system into their business. Their efforts have prepared them to enter the next tier to further integrate their key operational resources to include their external suppliers.

The temperature dependence of the specific contact resistance of W and WSi{sub 0.44} contacts on n{sup +} In{sub 0.65}Ga{sub 0.35}N and InN was measured in the range -50 {degrees}C to 125 {degrees}C. The results were compared to theoretical values for different conduction mechanisms, to further elucidate the conduction mechanism in these contact schemes for all but as-deposited metal to InN where thermionic emission appears to be the dominant mechanism. The contacts were found to produce low specific resistance ohmic contacts to InGaN at room temperature, e{sup c} {approximately} 10{sup -7} {Omega} {center_dot} cm{sup 2} for W and e{sub c} of 4x 10{sup -7} {Omega} {center_dot} cm{sup 2} for WSi{sub x}. InN metallized with W produced ohmic contacts with e{sub c} {approximately} 10{sup -7} {Omega} {center_dot} cm{sup 2} and e{sub c} {approximately} 10{sup -6} {Omega} {center_dot} cm{sup 2} for WSi{sub x} at room temperature.

Our studies of the shock compression response of PVDF polymer are continuing in order to understand the physical properties under shock loading and to develop high fidelity, reproducible, time-resolved dynamic stress gauges. New PVDF technology, new electrode configurations and piezoelectric analysis have resulted in enhanced precision gauges. Our new standard gauges have a precision of better than 1% in electric charge release under shock up to 15 GPa. The piezoelectric response of shock compressed PVDF gauges 1 mm{sup 2} in active area has been studied and yielded well-behaved reproducible data up to 20 GPa. Analysis of the response of these gauges in the {open_quotes}thin mode regime{close_quotes} using a Lagrangian hydrocode will be presented. P(VDF-TrFE) copolymers exhibit unique piezoelectric properties over a wide range of temperature depending on the composition. Their properties and phase transitions are being investigated. Emphasis of the presentation will be on key results and implications.

The wide gap materials SiC, GaN and to a lesser extent diamond are attracting great interest for high power/high temperature electronics. There are a host of device processing challenges presented by these materials because of their physical and chemical stability, including difficulty in achieving stable, low contact resistances, especially for one conductivity type, absence of convenient wet etch recipes, generally slow dry etch rates, the high temperatures needed for implant activation, control of suitable gate dielectrics and the lack of cheap, large diameter conducting and semi-insulating substrates. The relatively deep ionization levels of some of the common dopants (Mg, in GaN; B, Al in SiC; P in diamond) means that carrier densities may be low at room temperature even if the impurity is electrically active - this problem will be reduced at elevated temperature, and thus contact resistances will be greatly improved provided the metallization is stable and reliable. Some recent work with CoSi{sub x} on SiC and W-alloys on GaN show promise for improved ohmic contacts. The issue of unintentional hydrogen passivation of dopants will also be covered - this leads to strong increases in resistivity of p-SiC and GaN, but to large decreases in resistivity of diamond. Recent work on development of wet etches has found recipes for AlN (KOH), while photochemical etching of SiC and GaN has been reported. In the latter cases p-type materials is not etched, which can be a major liability in some devices. The dry etch results obtained with various novel reactors, including ICP, ECR and LE4 will be compared - the high ion densities in the former techniques produce the highest etch rates for strongly-bonded materials, but can lead to preferential loss of N from the nitrides and therefore to a highly conducting surface. This is potentially a major problem for fabrication of dry etched, recessed gate FET structures.

Sandia National Laboratories has developed a systematic approach for achieving high confidence in major products requiring high reliability for use in high-consequence applications. A high-consequence application is one in which product failure could result in significant loss of life, damage to major systems or to the environment, financial loss, or political repercussions. The application of this process has proven to be of significant benefit in the early identification, verification, and correction of potential product design and manufacturing process failure modes. Early identification and correction of these failures modes and the corresponding controls placed on safety-critical features, ensures product adherence to safety-critical design requirements, and enhances product quality, reliability, and the cost effectiveness of delivered products. Safety-critical features include design features such as materials and dimensions, as well as manufacturing features such as assembly processes, inspections, and testing.

N-CART (the National Spent Nuclear Fuel Program Cost Analysis and Risk Tool) is being developed to aid in low-risk, cost-effective, timely management of radioactive waste and spent nuclear fuel, and can therefore be used in management of mixed waste. N-CART provides evaluation of multiple alternatives and presents the consequences of proposed waste management activities in a clear and concise format. N-CART`s decision-aiding analyses include comparisons and sensitivity analyses of multiple alternatives and allows the user to perform quick turn-around {open_quotes}what if{close_quotes} studies to investigate various scenarios. Uncertainties in data (such as cost and schedule of various activities) are represented as distributions. N-CART centralizes documentation of the bases of program alternatives and program decisions, thereby supporting responses to stakeholders concerns. The initial N-CART design considers regulatory requirements, costs, and schedules for alternative courses of action. The final design will include risks (public health, occupational, economic, scheduling), economic benefits, and the impacts of secondary waste generation. An optimization tool is being incorporated that allows the user to specify the relative importance of cost, time risks, and other bases for decisions. The N-CART prototype can be used to compare the costs and schedules of disposal alternatives for mixed low-level radioactive waste (MLLW) and greater-than-Class-C (GTCC) waste, as well as spent nuclear fuel (SNF) and related scrap material.

The use of dendrimers for preparing chemically sensitive interfaces for detecting volatile organic compounds (VOCs) using surface acoustic wave (SAW) device transducers is described. Specifically, the synthesis of the dendrimers and the means by which they are affixed to SAW devices is discussed, followed by a detailed spectroscopic analysis of the surface-confined dendrimers and a discussion of their interaction with different VOCs. Most of these preliminary experiments focus on dendrimer surface modification using benzoylchloride, which leads to phenyl terminal groups linked to the dendrimer via amide groups. The results of this study lead us to conclude that dendrimers: (1) provide general specificity towards classes of functional groups and are therefore suitable for array-based sensing schemes; (2) are intermediate in structure between monolayers and polymers and exhibit the desirable properties of both; (3) can be straightforwardly attached to the surfaces of acoustic wave devices.

Boron-doped back-surface fields (BSF`s) have potentially superior performance compared to aluminum-doped BSF`s due to the higher solid solubility of boron compared to aluminum. However, conventional boron diffusions require a long, high temperature step that is both costly and incompatible with many photovoltaic-grade crystalline-silicon materials. We examined a process that uses a relatively low-temperature aluminum-alloy process to obtain a boron-doped BSF by doping the aluminum with boron. In agreement with theoretical expectations, we found that thicker aluminum layers and higher boron doping levels improved the performance of aluminum-alloyed BSF`s.

Zinc polyphosphate glasses were examined as potential candidates for low temperature sealing applications. Glass-formation and properties were determined for the ZnO-P{sub 2}O{sub 5}, ZnO-B{sub 2}O{sub 3}-P{sub 2}O{sub 5} and ZnO-SnO-P{sub 2}O{sub 5} systems, and information about the short-range structures of these glasses was obtained by Raman and solid state nuclear magnetic resonance spectroscopies. In general, the most durable polyphosphate glasses have structures based on relatively short pyrophosphate chain lengths (i.e., 2 P-tetrahedra). Modified phosphate compositions are given, including compositions used to seal float glass substrates at temperatures as low as 500{degrees}C.

The purpose of hazardous and radioactive materials packaging is to enable these materials to be transported without posing a threat to the health or property of the general public. To achieve this aim, regulations in the US have been written establishing general design requirements for such packagings. While no regulations have been written specifically for mixed waste packaging, regulations for the constituents of mixed wastes, i.e., hazardous and radioactive substances, have been codified by the US Department of Transportation and the US Nuclear Regulatory Commission. Based on these national requirements, a Chemical Compatibility Testing Program was developed in the Transportation Systems Department at SNL. In this paper, the authors present the results of Part B of the second phase of this testing program. The first phase screened five liner materials and six seal materials towards four simulant mixed wastes. Part A of the second phase involved the comprehensive testing of five candidate liner materials to an aqueous Hanford Tank simulant mixed waste. Part B involved similar testing on elastomeric materials, ethylene-propylene and butadiene-acrylonitrile rubber. The comprehensive testing protocol involved exposing the respective materials to a matrix of four gamma radiation doses ({approximately}1, 3, 6, and 40 kGy), three temperatures (18, 50, and 60 C), and four exposure times (7, 14, 28, and 180 days). Following their exposure to these combinations of conditions, the materials were evaluated by measuring six material properties. These properties were specific gravity, dimensional changes, hardness, vapor transport rates, compression set, and mechanical properties.

A survey of robotic applications in radioactive environments has been conducted, and analysis of robotic system components and their response to the varying types and strengths of radiation has been completed. Two specific robotic systems for accident recovery and nuclear fuel movement have been analyzed in detail for radiation hardness. Finally, a general design approach for radiation-hardened robotics systems has been developed and is presented. This report completes this project which was funded under the Laboratory Directed Research and Development program.

The theme of this year`s Annual Meeting is ``Ancient Wisdom-Future Technology.`` The panel assembled for this session has been asked to think metaphorically about the theme and how it relates to their profession of human factors and ergonomics. Originally conceived as a debate centering around the older technologies and research techniques versus the newer ways of finding answers, it was soon realized that there was no dichotomy, but more of a synergy between the old and the new. If human factors is truly a philosophy of design rather than simply a body of knowledge, then one would expect consistency in approach regardless of field of application or new discoveries of human performance. Just as when two or more rivers combine to become a force mightier than the simple summation, the synergistic power of established techniques or knowledge and recent innovation is available to everyone in the profession. The invited panelists represent diverse perspectives in human factors and ergonomics, and this made for a stimulating discussion.

Efficient techniques for rapid tritium removal will be necessary for ITER to meet its physics and engineering goals. One potential technique is transient surface heating by a scanning CO{sub 2} or Nd:Yag laser that would release tritium without the severe engineering difficulties of bulk heating of the vessel. The authors have modeled the heat propagation into a surface layer and find that a multi-kW/cm{sup 2} flux with an exposure time of order 10 ms is suitable to heat a 50 micron co-deposited layer to 1,000--2,000 degrees. Improved wall conditioning may be a significant side benefit. They identify remaining issues that need to be addressed experimentally.

A simultaneous PVDF/VISAR measurement technique was used for isentropic-loading experiments with a polymethyl methacrylate (PMMA) specimen. The experiments used a graded density impactor accelerated onto a tantalum driver backed with PMMA and then lithium fluoride windows for each experiment. Simultaneous measurements made at each window interface provided precise transit time and particle velocity measurements which can be used to determine the stress-vs-strain loading path using Lagrangian analysis techniques. The experimental technique provides access to 40 GPa stress levels in PMMA under isentropic-loading conditions.

Lightning data, recorded with satellite optical sensors, are compared with extremely low frequency (ELF) and Schumann resonance (SR) data from the Sprites `96 Campaign. The satellite data are broad-band visible events recorded by the M46 satellite payload. Full width at half maximum and optical tail durations from the satellite data are compared with ELF slow tail features and Schumann resonance spectral color. In addition, continuing current estimates were computed for several positive cloud-to-ground (PCG) strokes. These estimates were derived using relative optical intensities from the satellite data and a peak current measurement from National Lightning Detection Network (NLDN) data. This assessment of M46 lightning data supports correlations between visible and ELF signatures. More data must be studied for compelling proof.

Providing uncontaminated weapon internal atmosphere samples and measuring their dew points is of paramount importance for enhanced surveillance and accelerated aging. The authors are developing and integrating four types of gas sampling systems for use throughout the weapons complex. They are utilizing tools to extract time/age information from the gas analysis of weapon internal atmospheres.

This paper discusses the reliability of several photovoltaic projects including SMUD`s PV Pioneer project, various projects monitored by Ascension Technology, and the Colorado Parks project. System times-to-failure range from 1 to 16 years, and maintenance costs range from 1 to 16 cents per kilowatt-hour. Factors contributing to the reliability of these systems are discussed, and practices are recommended that can be applied to future projects. This paper also discusses the methodology used to collect and analyze PV system reliability data.

Vapor diffusion in porous media in the presence of its liquid has often been analyzed like air diffusion. The diffusion rate is much lower than in free space due to the presence of the porous medium and any liquid present. However, enhanced vapor diffusion has also been postulated such that the diffusion rate may approach free-space values. The mechanisms postulated to lead to this enhancement include condensation/evaporation across isolated liquid islands in the porous media and an increased temperature gradient in the gas phase. In order to try to understand the mechanisms involved in such an enhancement, pore-scale models have been developed. Vapor diffusion in the presence of liquid islands has been evaluated for a one-dimensional pore network under a concentration gradient. The simulations show that significant enhancement of vapor diffusion is indeed possible in the presence of liquid islands, while air diffusion decreases slightly. While the present pore-scale model indicates that enhanced vapor diffusion is possible, only experimental data can confirm the relevant processes.

Several analysis methods have been applied to evaluate the structure and composition of the electrode/adhesive interfaces i previously fielded M2370 Fire Sets. A method of interfacial fracture at cryogenic temperatures as been employed to expose regions of these interfaces at multiple levels in a SFE stack. Electron microscopy shows that bond failure induced by the fracture is predominantly adhesive with an equal probability of failure of the Au and Cu interfaces. Some evidence for cohesive, indicative of a possible microstructure related to electrical breakdown. Pinhole-free larger regions of adhesive also exist which may explain the observed high resistance in impedance measurements.

Shock-induced depoling of the ferroelectric PZT 95/5 has been utilized in pulsed power applications for many years. Recently, new design and certification requirements have generated a strong interest in numerically simulating the operation of pulsed power devices. Because of a scarcity of relevant experimental data obtained within the past twenty years, we have initiated an extensive experimental study of the dynamic behavior of this material in support of simulation efforts. The experiments performed to date have been limited to examining the behavior of unpoled material. Samples of PZT 95/5 have been shocked to axial stresses from 0.5 to 5.0 GPa in planar impact experiments. Impact face conditions have been recorded using PVDF stress gauges, and transmitted wave profiles have been recorded either at window interfaces or at a free surface using laser interferometry (VISAR). The results significantly extend the stresses examined in prior studies of unpoled material, and ensure that a comprehensive experimental characterization of the mechanical behavior under shock loading is available for continuing development of PZT 95/5 material models.

We describe a new approach to second-order nonlinear optical materials, namely quadrupoling. This approach is valid in the regime of Kleinman (full permutation) symmetry breaking, and thus requires a two- or three dimensional microscopic nonlinearity at wavelengths away from material resonances. This {open_quotes}quadrupolar{close_quotes} nonlinearity arises from the second rank pseudotensor of the rotationally invariant representation of the second-order nonlinear optical tensor. We have experimentally investigated candidate molecules comprised of chiral camphorquinone derivatives by measuring the scalar invariant associated with the rank two pseudotensor using hyper-Rayleigh scattering. We have found sizable scalar figures of merit for several compounds using light for which the second harmonic wavelengths are greater than 100 nm longer than the absorption peak location. At these wavelengths, the quadrupolar scalar is as large as the polar (EFISH) scalar of p-nitroaniline. Prospects for applications are discussed.

Electromagnetic (EM) methods, long used for borehole logging as a formation evaluation tool in developed oil fields, are rarely applied in surface or crosshole configurations or applied in cased wells. This is largely due to the high levels of cultural noise and the preponderance of steel well casing. However, recent experimental success with crosshole EM systems for water and steam flood monitoring using fiberglass cased wells has shown promise in applying these techniques to development and production (D & P) problems. This paper describes technological solutions that will allow for successful application of EM techniques in oil fields, despite surface noise and steel casing. First an example sites the application of long offset logging to map resistivity structure away from the borehole. Next, a successful application of crosshole EM where one of the wells is steel cased is described. The potential application of earth`s field nuclear magnetic resonance (NMR) to map fluid saturation at large distances from the boreholes is also discussed.

A fundamental understanding of aging in an organic material requires that one understand how aging affects the chemical structure of a material, and how these chemical changes are related to the material`s macroscopic properties. This level of understanding is usually achieved by examining the material on a variety of length scales ranging from atomic to meso-scale to macroscopic. The authors are developing and applying several {sup 13}C nuclear magnetic resonance (NMR) spectroscopy experiments to characterize the aging process of organic materials over a broad range of length scales. Examples of studies which range from atomic to macroscopic will be presented.

Errors in model parameters, sensing, and control are inevitably present in real robot systems. These errors must be considered in order to automatically plan robust solutions to many manipulation tasks. Lozano-Perez, Mason, and Taylor proposed a formal method for synthesizing robust actions in the presence of uncertainty; this method has been extended by several subsequent researchers. All of these results presume the existence of worst-case error bounds that describe the maximum possible deviation between the robot`s model of the world and reality. This paper examines the problem of measuring these error bounds for a real robot workcell. These measurements are difficult, because of the desire to completely contain all possible deviations while avoiding bounds that are overly conservative. The authors present a detailed description of a series of experiments that characterize and quantify the possible errors in visual sensing and motion control for a robot workcell equipped with standard industrial robot hardware. In addition to providing a means for measuring these specific errors, these experiments shed light on the general problem of measuring worst-case errors.

Multicrystalline-silicon (mc-Si) materials and cells feature large areal variations in material and junction quality. The regions with poor device quality have been predicted to have more recombination current at forward bias than a simple area-weighted average due to the parallel interconnection of the good and bad regions by the front junction. The authors have examined the effect of gettering on areal inhomogeneities in large-area mc-Si cells. Cells with large areal inhomogeneities were found to have increased non-ideal recombination current, which is in line with theoretical predictions. Phosphorus-diffusion and aluminum-alloy gettering of mc-Si was found to reduce the areal inhomogeneities and improve large-area mc-Si device performance.

Inductively coupled plasma etching of GaN, AlN, InN, InGaN and InAlN was investigated in CH{sub 4}/H{sub 2}/Ar plasmas as a function of dc bias, and ICP power. The etch rates were generally quite low, as is common for III-nitrides in CH{sub 4} based chemistries. The etch rates increased with increasing dc bias. At low rf power (150 W), the etch rates increased with increasing ICP power, while at 350 W rf power, a peak was found between 500 and 750 W ICP power. The etched surfaces were found to be smooth, while selectivities of etch were {le} 6 for InN over GaN, AlN, InGaN and InAlN under all conditions.

Gas guns and velocity interferometric techniques have been used to determine the loading behavior of an AD995 alumina rod 19 mm in diameter by 75 mm and 150 mm long, respectively. Graded-density materials were used to impact both bare and sleeved alumina rods while the velocity interferometer was used to monitor the axial-velocity of the free end of the rods. Results of these experiments demonstrate that (1) a time-dependent stress pulse generated during impact allows an efficient transition from the initial uniaxial strain loading to a uniaxial stress state as the stress pulse propagates through the rod, and (2) the intermediate loading rates obtained in this configuration lie between split Hopkinson bar and shock-loading techniques.

The B61 accelerated aging unit (AAU) provided a unique opportunity to document the effects of a controlled, long-term thermal cycling environment on the aging of materials used in the device. This experiment was of particular interest to solder technologists because thermal cycling environments are a predominant source of solder joint failures in electronic assemblies. Observations of through hole solder joints in the MC2918 Firing Set from the B61 AAU did not reveal signs of catastrophic failure. Quantitative analyses of the microstructural metrics of intermetallic compound layer thickness and Pb-rich phase particle distributions indicated solder joint aging that was commensurate with the accelerated aging environment. The effects of stress-enhanced coarsening of the Pb-rich phase were also documented.

Passive autocatalytic recombiners (PARs) are being considered by the nuclear power industry as a combustible gas control system in operating plants and advanced light water reactor (ALWR) containments for design basis events. Sandia National Laboratories (SNL) has developed systems and methodologies to measure the amount of hydrogen that can be depleted in a containment by a PAR. Experiments were performed that determined the hydrogen depletion rate of a PAR in the presence of steam and also evaluated the effect of scale (number of cartridges) on the PAR performance at both low and high hydrogen concentrations.

The US Department of Energy has recently completed a topical safety analysis report outlining the design and operation of a Centralized Interim Storage Facility for spent commercial nuclear fuel. During the course of the design, dose assessments indicated the need for remote operation of many of the cask handling operations. Use of robotic equipment was identified as a desirable handling solution that is capable of automating many of the operations to maintain throughput, and sufficiently flexible to handle five or more different storage cask designs in varying numbers on a given day. This paper discusses the facility and the dose assessment leading to this choice, and reviews factors to be considered when choosing robotics or automation. Further, a new computer simulation tool to quantify dose to humans working in radiological environments, the Radiological Environment Modeling System (REMS), is introduced. REMS has been developed to produce a more accurate estimate of dose to radiation workers in new activities with radiological hazards.

This document describes a Software Development Methodology for High Consequence Systems. A High Consequence System is a system whose failure could lead to serious injury, loss of life, destruction of valuable resources, unauthorized use, damaged reputation or loss of credibility or compromise of protected information. This methodology can be scaled for use in projects of any size and complexity and does not prescribe any specific software engineering technology. Tasks are described that ensure software is developed in a controlled environment. The effort needed to complete the tasks will vary according to the size, complexity, and risks of the project. The emphasis of this methodology is on obtaining the desired attributes for each individual High Consequence System.

Vector network analyzers are a convenient way to measure scattering parameters of a variety of microwave devices. However, these instruments, unlike oscilloscopes for example, require a relatively high degree of user knowledge and expertise. Due to the complexity of the instrument and of the calibration process, there are many ways in which an incorrect measurement may be produced. The Microwave Project, which is part of SNL`s Primary Standards laboratory, routinely uses check standards to verify that the network analyzer is operating properly. In the past, these measurements were recorded manually and, sometimes, interpretation of the results was problematic. To aid the measurement assurance process, a software program was developed to automatically measure a check standard and compare the new measurements with a historical database of measurements of the same device. The program acquires new measurement data from selected check standards, plots the new data against the mean and standard deviation of prior data for the same check standard, and updates the database files for the check standard. The program is entirely menu-driven requiring little additional work by the user. This report describes the function of the software, including a discussion of its capabilities, and the way in which the software is used in the lab.

Three Milliwatt Generator Heat Source (MWGHS) shelf-life-related capsules were pressure-burst tested after thermal aging. Shelf-life capsules PB-08-03 (MC2893) and MPT-11-33 (MC3599) were tested at 1,010 C and capsule PB-07-13 (MC2893) was tested at 1,100 C. Subsequent to pressure-burst testing, each capsule was bubble-leak tested then metallographically examined. Post-mortem evaluation consisted of metallography, microhardness, scanning electron microscopy (SEM), and oxygen and nitrogen analysis. Capsules PB-08-03 and PB-07-13 failed by elevated temperature stress-rupture in the coarse-grained cap to body welds, as has been documented for previous capsules. Pressure-burst testing of capsule MPT-11-33 was terminated prior to failure after 739 hours on test at 1,010 C, however, microscopic examination of the weld indicated that similar failure had began to occur in the interior portion of the capsule to body weld. Evidence was obtained indicating that metallurgical changes occurred during the pressure-burst test performed at 1,100 C. The metallurgical observations of a preferred site for elevated temperature deformation and fracture (the coarse-grained weld region) and structural instability (the property changes during testing at 1,100 C) need to be considered in component lifetime prediction and modeling efforts.

This paper briefly describes a prototype sensor for detecting land mines placed in shallow water. An automatic system was developed which incorporates chemical concentration technology, an ion mobility spectrometer, and control and fluid movement subsystems. The system design was successfully demonstrated using laboratory instruments and equipment. Components for the portable unit, which will weigh less than 20 pounds, have been fabricated; field demonstrations will be completed by spring 1998. 4 figs.

This paper discusses recent experiments in the manipulation and assembly of parts with 100 micron outside dimensions and submicron tolerances. The objective of this work is to develop a micromanipulation workcell which can automatically assemble LIGA (Lithography Galvonoforming Abforming) parts using an assembly plan and a CAD drawing of each of the components. The workcell consists of an AdeptOne robot, precision stages, long distance microscope, and a high aspect ratio modeled polysilicon tweezers for picking up the parts. Fourier optics methods are used to generate synthetic microscope images from CAD drawings. These synthetic images are used off-line to test image processing routines under varying magnifications an depths of field. They also provide reference image features which are used to visually servo the true part to the desired position.

Designers of components-based, real-time systems need to guarantee to correctness of soft-ware and its output. Complexity of a system, and thus the propensity for error, is best characterized by the number of states a component can encounter. In many cases, large numbers of states arise where the processing is highly dependent on context. In these cases, states are often missed, leading to errors. The following are proposals for compactly specifying system states which allow the factoring of complex components into a control module and a semantic processing module. Further, the need for methods that allow for the explicit representation of ambiguity and uncertainty in the design of components is discussed. Presented herein are examples of real-world problems which are highly context-sensitive or are inherently ambiguous.

Photovoltaic (PV) modules that provide only ac power give new dimensions to the use of, and utility interface of, PV systems because all of the dc issues are virtually eliminated. These AC PV modules offer the important advantage that customers may now purchase a PV system without hiring a design engineer. A qualified electrician will be able to install a complete PV system that performs as expected and meets local electrical codes. Simple installations of additional AC PV modules will be possible once the proper branch circuit wiring and protection have been installed. Codes and standards are currently being written to address the utility-interconnect issues for AC PV modules and other interactive inverters. An industry-supported Task Group has recently written and submitted proposals for changes to bring Article 690 of the 1999 National Electrical Code{reg_sign} (NEC{reg_sign}) up to the state-of-the-art for PV devices such as AC PV modules. This paper summarizes the proposed code changes and standards related to the evolving AC PV module technology in the United States. Topics such as the need for dedicated branch circuits for AC PV modules in residential applications are discussed and analyzed. Requirements for limiting the number of AC modules on a branch circuit and the listing requirements that make safe installations are discussed. Coordination of all standards activities for AC module installations, the building-integrated perspectives, and utility-interface issues is discussed.

The U.S. National Photovoltaic Program began in 1975 by supporting the development of terrestrial PV modules and hardware associated with grid-connected PV systems. Early PV-system demonstration programs were also supported and cost shared by the U.S. Department of Energy (DOE). A wide variety of PV systems were deployed, usually with utility participation. The early demonstration projects provided, and continue to provide, valuable PV system experience to utilities, designers and suppliers. As a result of experience gained, several important milestones in codes and standards pertaining to the design, installation and operation of photovoltaic (PV) systems have been completed. These code and standard activities were conducted through collaboration of participants from all sectors of the PV industry, utilities and the US DOE National Photovoltaic Program. Codes and standards that have been proposed, written, or modified include changes and additions for the 1999 National Electric Code{reg_sign} (NEC{reg_sign}), standards for fire and personnel safety, system testing, field acceptance, component qualification, and utility interconnection. Project authorization requests with the Institute of Electrical and Electronic Engineers (IEEE) have resulted in standards for component qualification and were further adapted for standards used to list PV modules and balance-of-system components. Industry collaboration with Underwriter Laboratories, Inc., with the American Society for Testing and Materials, and through critical input and review for international standards with the International Electrotechnical Commission have resulted in new and revised domestic and international standards for PV applications. Activities related to work on codes and standards through the International Energy Agency are also being supported by the PV industry and the US DOE. The paper shows relationships between activities in standards writing.

A new method to analyze human errors has been demonstrated at a pressurized water reactor (PWR) nuclear power plant. This was the first application of the new method referred to as A Technique for Human Error Analysis (ATHEANA). The main goals of the demonstration were to test the ATHEANA process as described in the frame-of-reference manual and the implementation guideline, test a training package developed for the method, test the hypothesis that plant operators and trainers have significant insight into the error-forcing-contexts (EFCs) that can make unsafe actions (UAs) more likely, and to identify ways to improve the method and its documentation. A set of criteria to evaluate the {open_quotes}success{close_quotes} of the ATHEANA method as used in the demonstration was identified. A human reliability analysis (HRA) team was formed that consisted of an expert in probabilistic risk assessment (PRA) with some background in HRA (not ATHEANA) and four personnel from the nuclear power plant. Personnel from the plant included two individuals from their PRA staff and two individuals from their training staff. Both individuals from training are currently licensed operators and one of them was a senior reactor operator {open_quotes}on shift{close_quotes} until a few months before the demonstration. The demonstration was conducted over a 5 month period and was observed by members of the Nuclear Regulatory Commission`s ATHEANA development team, who also served as consultants to the HRA team when necessary. Example results of the demonstration to date, including identified human failure events (HFEs), UAs, and EFCs are discussed. Also addressed is how simulator exercises are used in the ATHEANA demonstration project.

Sandia National Laboratories has developed a computer based model called IVSEM (Integrated Verification System Evaluation Model) to estimate the performance of a nuclear detonation monitoring system. The IVSEM project was initiated in June 1994, by Sandia`s Monitoring Systems and Technology Center and has been funded by the US Department of Energy`s Office of Nonproliferation and National Security (DOE/NN). IVSEM is a simple, top-level, modeling tool which estimates the performance of a Comprehensive Nuclear Test Ban Treaty (CTBT) monitoring system and can help explore the impact of various sensor system concepts and technology advancements on CTBT monitoring. One of IVSEM`s unique features is that it integrates results from the various CTBT sensor technologies (seismic, infrasound, radionuclide, and hydroacoustic) and allows the user to investigate synergy among the technologies. Specifically, IVSEM estimates the detection effectiveness (probability of detection) and location accuracy of the integrated system and of each technology subsystem individually. The model attempts to accurately estimate the monitoring system`s performance at medium interfaces (air-land, air-water) and for some evasive testing methods such as seismic decoupling. This report describes version 1.2 of IVSEM.

The use of computational modeling to improve equipment and process designs for chemical vapor deposition (CVD) reactors is becoming increasingly common. Commercial codes are available that facilitate the modeling of chemically-reacting flows, but chemical reaction mechanisms must be separately developed for each system of interest. One f the products of the Watkins-Johnson Company (WJ) is a reactor marketed to semiconductor manufacturers for the atmospheric-pressure chemical vapor deposition (APCVD) of silicon oxide films. In this process, TEOS (tetraethoxysilane, Si(OC{sub 2}H{sub 5}){sub 4}) and ozone (O{sub 3}) are injected (in nitrogen and oxygen carrier gases) over hot silicon wafers that are being carried through the system on a moving belt. As part of their equipment improvement process, WJ is developing computational models of this tool. In this effort, they are collaborating with Sandia National Laboratories (SNL) to draw on Sandia`s experience base in understanding and modeling the chemistry of CVD processes.

Self Assembled (SA) thin films and Langmuir-Blodgett (LB) thin films are emerging technologies for the development of chemical and bio-chemical sensors, electrooptic films, second harmonic generators (frequency doublers), templates for biomimetic growth etc. One of the goals of this project was to extend Sandia`s characterization techniques and molecular modeling capabilities for these complex two-dimensional geometries with the objective of improving the control of the fabrication of these structures for specific applications. Achieving this requires understanding both the structure throughout the thickness of the films and the in-plane lattice of the amphiphilic molecules. To meet these objectives they used atomic force microscopy (AFM), X-ray reflectivity, and molecular modeling. While developing these capabilities, three different materials systems were fabricated and characterized: (1) Self Assembled Monolayers (SAMs) of octadecyltrichlorosilane (OTS) and LB films of arachidic acid on silicon wafers; (2) SAMs on PZT substrates; and (3) electrochemical deposition of CdS on LB film templates.

This report addresses the need for government sponsored R and D to address real public problems. The motivation is that a public benefit of the money spent must be demonstrated. The areas identified as not having appropriate attention resulting in unmet public needs include healthcare cost, cost and benefits of regulations, infrastructure problems, defense spending misaligned with foreign policy objectives, the crime problem, energy impact on the environment, the education problem, low productivity growth industry sectors, the income distribution problem, the aging problem, the propagation of disease and policy changes needed to address the solution of these problems.

The goal of this project was to develop a novel technology that may be used to eventually manufacture a new generation of inorganic membranes and sensors with oriented, unidirectional monosized pores. The premise is that very thin membranes with oriented channels as pores will have a high flux in addition to being highly selective. Applications include: (1) gas separation membranes for oxygen enrichment, partial oxidation, dehydrogenation, and purification of natural gas; (2) refractory catalytic membrane reactors; and (3) molecular recognition sensors. The methodology for making such membranes was to combine Langmuir - Blodgett (LB) technology with sol-gel chemistry to engineer pore channels within the range 3 to 20 K The channel structure was fabricated of amorphous SiO{sub 2} because of its good thermal, chemical, and mechanical stability. Our approach was to use LB techniques to uniformly place organic molecular spacers throughout a thin silica precursor matrix and apply this film to a substrate. LB films of solid solutions of commercially available silane amphiphiles and organic amphiphiles were fabricated. The siloxane groups were then hydrolyzed to form silica and the organic portions of the amphiphiles removed by thermal decomposition. With the completely fugitive organic spacer amphiphiles removed, a thin silica film with micropores resulted. The pore size was in the range of 6 - 8 {angstrom} and in an ultra-thin configuration. With further development this technique may be useful for fabrication of inorganic membranes which satisfy all the criteria of the ideal membrane.

Nuclear power plants are converting to digital instrumentation and control systems; however, the effects of abnormal environments such as fire and smoke on such systems are not known. There are no standard tests for smoke, but previous smoke exposure tests at Sandia National Laboratories have shown that digital communications can be temporarily interrupted during a smoke exposure. Another concern is the long-term corrosion of metals exposed to the acidic gases produced by a cable fire. This report documents measurements of basic functional circuits during and up to 1 day after exposure to smoke created by burning cable insulation. Printed wiring boards were exposed to the smoke in an enclosed chamber for 1 hour. For high-resistance circuits, the smoke lowered the resistance of the surface of the board and caused the circuits to short during the exposure. These circuits recovered after the smoke was vented. For low-resistance circuits, the smoke caused their resistance to increase slightly. A polyurethane conformal coating substantially reduced the effects of smoke. A high-speed digital circuit was unaffected. A second experiment on different logic chip technologies showed that the critical shunt resistance that would cause failure was dependent on the chip technology and that the components used in the smoke exposures were some of the most smoke tolerant. The smoke densities in these tests were high enough to cause changes in high impedance (resistance) circuits during exposure, but did not affect most of the other circuits. Conformal coatings and the characteristics of chip technologies should be considered when designing circuitry for nuclear power plant safety systems, which must be highly reliable under a variety of operating and accident conditions. 10 refs., 34 figs., 18 tabs.

A message-passing version of the PAGOSA shock-wave physics code has been developed at Sandia National Laboratories for multiple-instruction, multiple-data stream (MIMD) computers. PAGOSA is an explicit, Eulerian code for modeling the three-dimensional, high-speed hydrodynamic flow of fluids and the dynamic deformation of solids under high rates of strain. It was originally developed at Los Alamos National Laboratory for the single-instruction, multiple-data (SIMD) Connection Machine parallel computers. The performance of Sandia`s message-passing version of PAGOSA has been measured on two MIMD machines, the nCUBE 2 and the Intel Paragon XP/S. No special efforts were made to optimize the code for either machine. The measured scaled speedup (computational time for a single computational node divided by the computational time per node for fixed computational load) and grind time (computational time per cell per time step) show that the MIMD PAGOSA code scales linearly with the number of computational nodes used on a variety of problems, including the simulation of shaped-charge jets perforating an oil well casing. Scaled parallel efficiencies for MIMD PAGOSA are greater than 0.70 when the available memory per node is filled (or nearly filled) on hundreds to a thousand or more computational nodes on these two machines, indicating that the code scales very well. Thus good parallel performance can be achieved for complex and realistic applications when they are first implemented on MIMD parallel computers.

A contact enforcement algorithm has been developed for matrix-free quasistatic finite element techniques. Matrix-free (iterative) solution algorithms such as nonlinear Conjugate Gradients (CG) and Dynamic Relaxation (DR) are distinctive in that the number of iterations required for convergence is typically of the same order as the number of degrees of freedom of the model. From iteration to iteration the contact normal and tangential forces vary significantly making contact constraint satisfaction tenuous. Furthermore, global determination and enforcement of the contact constraints every iteration could be questioned on the grounds of efficiency. This work addresses this situation by introducing an intermediate iteration for treating the active gap constraint and at the same time exactly (kinematically) enforcing the linearized gap rate constraint for both frictionless and frictional response.

The aim of this project was to develop the capabilities for Sandia to fabricate self assembled Langmuir-Blodgett (LB) films of various materials and to exploit their two-dimensional crystalline structure to promote the growth of oriented thin films of inorganic materials at room temperature. This includes the design and synthesis of Langmuir-active (amphiphilic) organic molecules with end groups offering high nucleation potential for various ceramics. A longer range goal is that of understanding the underlying principles, making it feasible to use the techniques presented in this report to fabricate unique oriented films of various materials for electronic, sensor, and membrane applications. Therefore, whenever possible, work completed in this report was completed with the intention of addressing the fundamental phenomena underlying the growth of crystalline, inorganic films on template layers of highly organized organic molecules. This problem was inspired by biological processes, which often produce exquisitely engineered structures via templated growth on polymeric layers. Seashells, for example, exhibit great toughness owing to their fine brick-and-mortar structure that results from templated growth of calcium carbonate on top of layers of ordered organic proteins. A key goal in this work, therefore, is to demonstrate a positive correlation between the order and orientation of the template layer and that of the crystalline ceramic material grown upon it. The work completed was comprised of several parallel efforts that encompassed the entire spectrum of biomimetic growth from solution. Studies were completed on seashells and the mechanisms of growth for calcium carbonate. Studies were completed on the characterization of LB films and the capability developed for the in-house fabrication of these films. Standard films of fatty acids were studied as well as novel polypeptides and porphyrins that were synthesized.

Three relatively simple mathematical models have been developed to estimate minimum reactor and radiation shield masses for liquid-metal-cooled reactors (LMRs), in-core thermionic fuel element (TFE) reactors, and out-of-core thermionic reactors (OTRs). The approach was based on much of the methodology developed for the Reactor/Shield Mass (RSMASS) model. Like the original RSMASS models, the new RSMASS-derivative (RSMASS-D) models use a combination of simple equations derived from reactor physics and other fundamental considerations, along with tabulations of data from more detailed neutron and gamma transport theory computations. All three models vary basic design parameters within a range specified by the user to achieve a parameter choice that yields a minimum mass for the power level and operational time of interest. The impact of critical mass, fuel damage, and thermal limitations are accounted for to determine the required fuel mass. The effect of thermionic limitations are also taken into account for the thermionic reactor models. All major reactor component masses are estimated, as well as instrumentation and control (I&C), boom, and safety system masses. A new shield model was developed and incorporated into all three reactor concept models. The new shield model is more accurate and simpler to use than the approach used in the original RSMASS model. The estimated reactor and shield masses agree with the mass predictions from separate detailed calculations within 15 percent for all three models.

In 1967, Sandia National Laboratories published empirical equations to predict penetration into natural earth materials and concrete. Since that time there have been several small changes to the basic equations, and several more additions to the overall technique for predicting penetration into soil, rock, concrete, ice, and frozen soil. The most recent update to the equations was published in 1988, and since that time there have been changes in the equations to better match the expanding data base, especially in concrete penetration. This is a standalone report documenting the latest version of the Young/Sandia penetration equations and related analytical techniques to predict penetration into natural earth materials and concrete. 11 refs., 6 tabs.

This technical report describes some lessons learned from implementing the Message Passing Interface (MPI) standard, and some proposed extentions to MPI, at Sandia. The implementations were developed using Sandia-developed lightweight kernels running on the Intel Paragon and Intel TeraFLOPS platforms. The motivations for this research are discussed, and a detailed analysis of several implementation issues is presented.

The initial National Emission Standards for Hazardous Air Pollutants (NESHAP - 40 CFR 61, Subpart H) Program at Sandia National Laboratories, New Mexico (SNL/NM) required: (1) continuous air monitoring of sources if the calculated effective dose equivalent (EDE) to the maximum exposed individual (MEI) was > 0.1 mrem/yr; (2) the determination of emissions based on measurements or measured parameters if the EDE to the MEI was < 0.1 mrem/yr; and (3) the calculation of worst case releases when the expected air concentrations were below detection limits using standard monitoring equipment. This conservative interpretation of the regulation guided SNL/NM to model, track, and trend virtually all emission sources with the potential to include any radionuclides. The level of effort required to implement these activities was independent of the EDE contributing from individual sources. A recent programmatic review found the NESHAP program to be in excess of the legal requirements. A further review found that, in summation, 13 of 16 radionuclide sources had a negligible impact on the final calculated EDE to the MEI used to demonstrate compliance at 20 separate on-site receptor locations. A reevaluation was performed to meet the legal requirements of 40 CFR 61, Subpart H, and still be reasonable and appropriate under the existing circumstances.

Questions have arisen regarding the applicability of seismic sensors to detect mining (re-entry) with a tunnel boring machine (TBM). Unlike cut and blast techniques of mining which produce impulsive seismic signals, the TBM produces seismic signals which are of long duration. (There are well established techniques available for detecting and locating the sources of the impulsive signals.) The Yucca Mountain repository offered an opportunity to perform field evaluations of the capabilities of seismic sensors because during much of 1996, mining there was progressing with the use of a TBM. During the mining of the repository`s southern branch, an effort was designed to evaluate whether the TBM could be detected, identified and located using seismic sensors. Three data acquisition stations were established in the Yucca Mountain area to monitor the TBM activity. A ratio of short term average to long term average algorithm was developed for use in detection based on the characteristics shown in the time series. For location of the source of detected signals, FK analysis was used on the array data to estimate back azimuths. The back azimuth from the 3 component system was estimated from the horizontal components. Unique features in the timing of the seismic signal were used to identify the source as the TBM.

In this paper, the major elements of the site selection and characterization processes used in the US high level waste program are discussed. While much of the evolution of the site selection and characterization processes have been driven by the unique nature of the US program, these processes, which are well defined and documented, could be used as an initial basis for developing site screening, selection, and characterization programs in other countries. Thus, this paper focuses more on the process elements than the specific details of the US program.

In this paper the authors report on the direct bonding of compound semiconductors and silicon annealed at low temperatures (400 C) using hydrogen and nitrogen. Pressure and temperature relationships on interface characteristics were investigated with high resolution transmission electron microscopy and energy dispersive x-ray spectroscopy. It was found that no morphology differences existed between hydrogen and nitrogen annealed samples. applying the N{sub 2} bonding process, 850nm bottom emitting vertical cavity surface emitting lasers (VCSELs), were bonded to a transparent AlGaAs substrate. Finally, high anneal temperatures (up to 450 C) and shear stress values (> 1.6 MPa) were obtained for GaAs bonded to Si using a dry (plasma) activation technique.

CONTAIN is a reactor accident simulation code developed by Sandia National Laboratories under US Nuclear Regulatory Commission (USNRC) sponsorship to provide integrated analysis of containment phenomena, including those related to nuclear reactor containment loads and radiological source terms. The recently released CONTAIN 2.0 code version represents a significant advance in CONTAIN modeling capabilities over the last major code release (CONTAIN 1.12V). The new modeling capabilities are discussed here. The principal motivation for many of the recent model improvements has been to allow CONTAIN to model the special features in advanced light water reactor (ALWR) designs. The work done in this area is also summarized. In addition to the ALWR work, the USNRC is currently engaged in an effort to qualify CONTAIN for more general use in licensing, with the intent of supplementing or possibly replacing traditional licensing codes. To qualify the CONTAIN code for licensing applications, studies utilizing CONTAIN 2.0 are in progress. A number of results from this effort are presented in this paper to illustrate the code capabilities. In particular, CONTAIN calculations of the NUPEC M-8-1 and ISP-23 experiments and CVTR test {number_sign}3 are presented to illustrate (1) the ability of CONTAIN to model non-uniform gas density and/or temperature distributions, and (2) the relationship between such gas distributions and containment loads. CONTAIN and CONTEMPT predictions for a large break loss of coolant accident scenario in the San Onofre plant are also compared.

Radiation and Nuclear Safety Authority (STUK), Helsinki, Finland and Sandia National Laboratories (SNL), working under the Finnish Support Program to IAEA Safeguards and the United States Department of Energy (DOE) funded International Remote Monitoring Program (Task FIN E 935), have undertaken a joint effort to demonstrate the use of remote monitoring for environmental air sampling and safeguards applications. The results of the task will be used by the IAEA to identify the feasibility, cost-effectiveness, reliability, advantages, and problems associated with remote environmental monitoring. An essential prerequisite for a reliable remote air sampling system is the protection of samples against tampering. Means must be developed to guarantee that the sampling itself has been performed as designed and the original samples are not substituted with samples produced with other equipment at another site. One such method is to label the samples with an unequivocal tag. In addition, the inspection personnel must have the capability to remotely monitor and access the automated environmental air sampling system through the use of various sensors and video imagery equipment. A unique aspect to this project is the network integration of remote monitoring equipment with a STUK radiation monitoring system. This integration will allow inspectors to remotely view air sampler radiation data and sensor/image data through separate software applications on the same review station. A sensor network and video system will be integrated with the SNL developed Modular Integrated Monitoring System (MIMS) to provide a comprehensive remote monitoring approach for safeguards purposes. This field trial system is being implemented through a multiphase approach for use by STUK, SNL, and for possible future use by the IAEA.

The present paper addresses the question: ``What are the general classes of uncertainty and error sources in complex, computational simulations?`` This is the first step of a two step process to develop a general methodology for quantitatively estimating the global modeling and simulation uncertainty in computational modeling and simulation. The second step is to develop a general mathematical procedure for representing, combining and propagating all of the individual sources through the simulation. The authors develop a comprehensive view of the general phases of modeling and simulation. The phases proposed are: conceptual modeling of the physical system, mathematical modeling of the system, discretization of the mathematical model, computer programming of the discrete model, numerical solution of the model, and interpretation of the results. This new view is built upon combining phases recognized in the disciplines of operations research and numerical solution methods for partial differential equations. The characteristics and activities of each of these phases is discussed in general, but examples are given for the fields of computational fluid dynamics and heat transfer. They argue that a clear distinction should be made between uncertainty and error that can arise in each of these phases. The present definitions for uncertainty and error are inadequate and. therefore, they propose comprehensive definitions for these terms. Specific classes of uncertainty and error sources are then defined that can occur in each phase of modeling and simulation. The numerical sources of error considered apply regardless of whether the discretization procedure is based on finite elements, finite volumes, or finite differences. To better explain the broad types of sources of uncertainty and error, and the utility of their categorization, they discuss a coupled-physics example simulation.

Tritium retention and removal are critical issues for the success of ITER or any DT fusion reactor. The Tokamak Fusion Test Reactor, TFTR, is the first fusion facility to afford the opportunity to study the tritium retention and removal over an extended period. In TFTR, tritium accumulates on all surfaces with line of sight to the plasma by codeposition of tritium with carbon. Measurements of both deuterium and tritium retention fractions have yielded retention between 0.2 and 0.6 of the injected fuel in the torus. Tritium has been successfully removed from TFTR by glow discharge cleaning and by air purges. The in-vessel inventory was reduced by a factor of 2, facilitating machine maintenance. In TFTR, the amount of dust recovered from the TFTR vacuum vessel has varied from several grams to a few kilograms.

The primary purpose of this LDRD was to identify and optimize materials as solid acid catalysts for the replacement of environmentally hazardous liquid acids such as H{sub 2}SO{sub 4} and HF which are used as catalysts in both the petroleum and chemical industries. Liquid acids have significant safety, environmental and engineering difficulties associated with their use in process chemistry. Special equipment/materials need to be used with liquid acids. Hydrofluoric acid poses unique safety problems due to it insipid attack on skin and tissue as well as its tendency to plume and travel long distances as a plume when it is released in the atmosphere. Therefore, any time a solid acid catalyst can be used to replace a liquid acid in a processes step, significant environmental, safety, and financial gains can be realized. The majority of work in this LDRD was performed on novel mixed metal phosphates which are a new solid acid catalyst material. Primarily the model reaction, 2-methyl-2-pentene isomerization, was used to determine acidity. These materials were tested for their activity, their deactivation and their stability. In addition, some of the phosphate materials were synthesized using templates in order to try to form a three dimensional network material from these phosphates. The amorphous sulfated zirconium-titanium phosphates were more acidic, as measured by olefin isomerization, than sulfated zirconia. However, they showed some of the same failings as sulfated zirconia in that they deactivated quickly and lost sulfur in a reducing atmosphere. Certain of the mixed metal phosphates, particularly tantalum-containing phosphates, showed strong acidity compared to sulfated zirconia as measured by olefin isomerization reaction.

No abstract available.

Two field tests of the surface area modulation (SAM) downhole wireless telemetry system were performed at the DOE Rocky Mountain Oilfield Testing Center near Casper, Wyoming in November, 1995 and September, 1996. SAM telemetry involves the introduction of a gap of electrically insulating material in the tubular conductors in the well. The electrical resistance of a switch in this gap can then be modulated to alter the electrical characteristics of a circuit involving the well tubulars. These changes affect the current in the circuit, which is monitored with a surface ammeter. Downhole data are encoded and transmitted to the surface as a pattern of current oscillations. The tests successfully demonstrated the ability of the system to transmit information from depths exceeding 2,000 feet to the surface at up to 2,400 baud.

No abstract available.

The goal of the 6th International Meshing Roundtable is to bring together researchers and developers from industry, academia, and government labs in a stimulating, open environment for the exchange of technical information related to the meshing process. In the pas~ the Roundtable has enjoyed significant participation born each of these groups from a wide variety of countries. The Roundtable will consist of technical presentations from contributed papers and abstracts, two invited speakers, and two invited panels of experts discussing topics related to the development and use of automatic mesh generation tools. In addition, this year we will feature a "Bring Your Best Mesh" competition and poster session to encourage discussion and participation from a wide variety of mesh generation tool users. The schedule and evening social events are designed to provide numerous opportunities for informal dialog. A proceedings will be published by Sandia National Laboratories and distributed at the Roundtable. In addition, papers of exceptionally high quaIity will be submitted to a special issue of the International Journal of Computational Geometry and Applications. Papers and one page abstracts were sought that present original results on the meshing process. Potential topics include but are got limited to: Unstructured triangular and tetrahedral mesh generation Unstructured quadrilateral and hexahedral mesh generation Automated blocking and structured mesh generation Mixed element meshing Surface mesh generation Geometry decomposition and clean-up techniques Geometry modification techniques related to meshing Adaptive mesh refinement and mesh quality control Mesh visualization Special purpose meshing algorithms for particular applications Theoretical or novel ideas with practical potential Technical presentations from industrial researchers.

Applications where O-rings are used to isolate atmospheric environments within a structure are critical to weapon reliability. Failure occurs when gases are able to travel from one side of the O-ring to the other. The anticipated cause of failure is the relaxation of the rubber over decades, the reduction in closure force, and the O-ring`s consequent inability to offer a barrier to gas transport. A predictive model with tractable complexity has been developed to predict the time over which an O-ring is able to maintain an acceptable value of closure force.

Sandia National Laboratories is developing a new technology to fabricate three-dimensional metallic components directly from CAD solid models. This process, called Laser Engineered Net Shaping (LENS{trademark}), exhibits enormous potential to revolutionize the way in which metal parts, such as complex prototypes, tooling, and small lot production parts, are produced. To perform the process, metal powder is injected into a molten pool created by a focused, high powered laser beam. Simultaneously, the substrate on which the deposition is occurring is scanned under the beam/powder interaction zone to fabricate the desired cross-sectional geometry. Consecutive layers are sequentially deposited, thereby producing a three-dimensional metal component.

Present and future space-based applications such as sensors, low-weight and low-power data links for satellites, communication between electromagnetically-shielded modules, and short-distance cross-links within satellite constellations may benefit from the inclusion of small, low-power, and high-efficiency lasers such as the recently-developed Vertical Cavity Surface-Emitting Laser (VCSEL). Many factors influence the application of these devices to space. Temperature response, operational lifetime and reliability, and power consumption are all important considerations for space applications. In addition, the space radiation environments must be considered. In this work, the effects of ionizing radiation on VCSELs are studied with an emphasis on proton damage, and with comparisons to related neutron and gamma-induced phenomena. The influence of proton irradiation is studied in-depth for selected VCSEL structures by the use of an ion microbeam. The experiments indicate that VCSELs exhibit much less threshold current shift for a given radiation dose, compared to the more traditional edge-emitting semiconductor lasers, but that self-heating is a more important consideration for VCSELs. The high current densities associated with VCSELs also lead to a strong influence from forward-bias annealing. These effects are common to various VCSEL types (780 nm and 850 nm) and their magnitude at a given dose is strongly dependent on device size. This indicates that, while VCSELs appear to be very insensitive to ionizing radiation when compared with alternative technologies, there are a number of factors that must be taken into account when optimizing for the space environment.

The number of commercial airframes exceeding twenty years of service continues to grow. In addition, Service Life Extension Programs are attempting to extend the {open_quotes}economic{close_quotes} service life of commercial airframes to thirty years. The use of bonded composites may offer the airframe manufacturers and aircraft maintenance facilities a cost effective method to extend the lives of their aircraft. The Federal Aviation Administration Assurance NDI Validation Center (AANC) to validate the use of bonded composite doublers on commercial aircraft.

For elastomers that will be used in applications involving long lifetimes, it is often necessary to first carry out and model accelerated aging experiments at higher than ambient temperatures, and then extrapolate the results in order to make lifetime predictions at the use temperature. Continuing goals in such endeavors are to better understand potential problems with such modeling approaches and to find ways of improving confidence in the predictions when the data are extrapolated. In this paper we will address several important issues involved in these procedures for elastomers exposed to air (oxygen), and discuss some potentially useful techniques and approaches which can increase confidence in lifetime predictions.

The technology developed in this project uses biometric information printed on the document and public key cryptography to ensure that an adversary cannot issue identification documents to unauthorized individuals or alter existing documents to allow their use by unauthorized individuals. This process can be used to produce many types of identification documents with much higher security than any currently in use. The system is demonstrated using a security badge as an example. This project focused on the technologies requiring development in order to make the approach viable with existing badge printing and laminating technologies. By far the most difficult was the image processing required to verify that the picture on the badge had not been altered. Another area that required considerable work was the high density printed data storage required to get sufficient data on the badge for verification of the picture. The image processing process was successfully tested, and recommendations are included to refine the badge system to ensure high reliability. A two dimensional data array suitable for printing the required data on the badge was proposed, but testing of the readability of the array had to be abandoned due to reallocation of the budgeted funds by the LDRD office.

The very general problem of model reduction of nonlinear systems was made tractable by focusing on the very large subclass consisting of linear subsystems connected by nonlinear interfaces. Such problems constitute a large part of the nonlinear structural problems encountered in addressing the Sandia missions. A synthesis approach to this class of problems was developed consisting of: detailed modeling of the interface mechanics; collapsing the interface simulation results into simple nonlinear interface models; constructing system models by assembling model approximations of the linear subsystems and the nonlinear interface models. These system models, though nonlinear, would have very few degrees of freedom. A paradigm problem, that of machine tool vibration, was selected for application of the reduction approach outlined above. Research results achieved along the way as well as the overall modeling of a specific machine tool have been very encouraging. In order to confirm the interface models resulting from simulation, it was necessary to develop techniques to deduce interface mechanics from experimental data collected from the overall nonlinear structure. A program to develop such techniques was also pursued with good success.

Multivariate calibration methods have been applied extensively to the quantitative analysis of Fourier transform infrared (FT-IR) spectral data. Partial least squares (PLS) methods have become the most widely used multivariate method for quantitative spectroscopic analyses. Most often these methods are limited by model error or the accuracy or precision of the reference methods. However, in some cases, the precision of the quantitative analysis is limited by the noise in the spectroscopic signal. In these situations, the precision of the PLS calibrations and predictions can be improved by the incorporation of weighting in the PLS algorithm. If the spectral noise of the system is known (e.g., in the case of detector-noise-limited cases), then appropriate weighting can be incorporated into the multivariate spectral calibrations and predictions. A weighted PLS (WPLS) algorithm was developed to improve the precision of the analysis in the case of spectral-noise-limited data. This new PLS algorithm was then tested with real and simulated data, and the results compared with the unweighted PLS algorithm. Using near-infrared (NIR) calibration precision when the WPLS algorithm was applied. The best WPLS method improved prediction precision for the analysis of one of the minor components by a factor of nearly 9 relative to the unweighted PLS algorithm.

A laboratory-scale experimental test system for small-scale of shock phenomena has been assembled. This system uses a variety of miniature test platforms in which shock loading is provided by laser-driven flyer impact. Acceptor materials include thin-film explosives and high-density metal foils. Optical access is provided for high-speed optical diagnostics such as optically recording velocity interferometry and single-pulse Raman spectroscopy. The experimental assembly for Raman studies features a common laser source for both flyer generation and excitation of Raman scattering (to achieve high timing precision) and a detection scheme that uses the coupling fiber for the excitation source to collect with high efficiency backscattered Raman light. Preliminary system evaluation experiments indicate that detailed particle velocity studies of the dynamic material properties of high-density metals under short-pulse, high-strain-rate loading can be performed in a miniaturized test configuration. Single-pulse Raman studies on shock compressed thin film explosives also appear feasible if the thickness and grain structure of these films can be tailored to enhance the Raman scattering signal sufficiently. Possible improvements in the experimental design and a number of likely applications of these techniques are also discussed.

The wide gap materials SiC, GaN and to a lesser extent diamond are attracting great interest for high power/high temperature electronics. There are a host of device processing challenges presented by these materials because of their physical and chemical stability, including difficulty in achieving stable, low contact resistances, especially for one conductivity type, absence of convenient wet etch recipes, generally slow dry etch rates, the high temperatures needed for implant activation, control of suitable gate dielectrics and the lack of cheap, large diameter conducting and semi-insulating substrates. The relatively deep ionization levels of some of the common dopants (Mg in GaN; B, Al in SiC; P in diamond) means that carrier densities may be low at room temperature, and thus contact resistances will be greatly improved provided the metallization is stable and reliable. Some recent work with CoSi{sub x} on SiC and W-alloys on GaN show promise for improved ohmic contacts. The issue of unintentional hydrogen passivation of dopants will also be covered - this leads to strong increases in resistivity of p-SiC and GaN, but to large decreases in resistivity of diamond. Recent work on development of wet etches has found recipes for AlN (KOH), while photochemical etching of SiC and GaN has been reported. In the latter cases p-type materials is not etched, which can be a major liability in some devices. The dry etch results obtained with various novel reactors, including ICP, ECR and LE4 will be compared - the high ion densities in the former techniques produce the highest etch rates for strongly-bonded materials, but can lead to preferential loss of N from the nitrides and therefore to a highly conducting surface. This is potentially a major problem for fabrication of dry etched, recessed gate FET structures.