Applications of microstructural modeling
This paper describes the use of computerized simulation to model microstructures of various materials.
This paper describes the use of computerized simulation to model microstructures of various materials.
Thermally activated (``thermal``) batteries have been used for ordnance applications (e.g., proximity fuzes) since World War II and, subsequent to that, in nuclear weapons. This technology was developed by the Germans as a power source for their V2 rockets. It was obtained by the Allies by interrogation of captured German scientists after the war. The technology developed rapidly from the initial primitive systems used by the Germans to one based on Ca/CaCrO{sub 4}. This system was used very successfully into the late 1970s, when it was replaced by the Li-alloy/FeS{sub 2} electrochemical system. This paper describes the predominant electrochemical couples that have been used in thermal batteries over the years. Major emphasis is placed on the chemistry and electrochemistry of the Ca/CaCrO{sub 4} and Li-alloy/FeS{sub 2} systems. The reason for this is to give the reader a better appreciation for the advances in thermal-battery technology for which these two systems are directly responsible. Improvements to date in the current Li-alloy/FeS{sub 2} and related systems are discussed and areas for possible future research and development involving anodes, cathodes, electrolytes, and insulations are outlined. New areas where thermal-battery technology has potential applications are also examined.
The current publicly released version of the Integrated TIGER Series (ITS), Version 3.0, has been widely distributed both domestically and internationally, and feedback has been very positive. This feedback as well as our own experience have convinced us to upgrade the system in order to honor specific user requests for new features and to implement other new features that will improve the physical accuracy of the system and permit additional variance reduction. This presentation we will focus on components of the upgrade that (1) improve the physical model, (2) provide new and extended capabilities to the three-dimensional combinatorial-geometry (CG) of the ACCEPT codes, and (3) permit significant variance reduction in an important class of radiation effects applications.
Several wellbore hydraulic models have been examined to determine their applicability in measuring the characteristics of lost circulation zones encountered in geothermal drilling. Characteristics such as vertical location in the wellbore, fracture size, effective permeability, and formation pressure must be known in order to optimize treatment of such zones. The models that have been examined to date are a steady-state model, a standpipe-pressure model, a raising-the-drill-bit model, a mud-weight model, a hydrofracture model, and several time-dependent models. None of these models yet have been found to adequately match the field data obtained from six loss zones in three geothermal wells. The development of these models is presented in this paper, and a discussion of their limitations is provided.
Short communication.
Oxide electrode technology is investigated for optimization of Pb(Zr,Ti)O{sub 3} (PZT) thin film capacitor properties for high density nonvolatile memory applications. PZT thin film capacitors with RF sputter deposited La{sub 0.5}Sr{sub 0.5}CoO{sub 3} (LSCO) electrodes have been characterized with respect to the following parameters: initial dielectric hysteresis loop characteristics, fatigue performance, microstructure and imprint behavior. Our studies have determined that the fatigue of PZT capacitors with LSCO electrodes is less sensitive to B site cation ratio and underlying electrode stack technology than with RuO{sub 2} electrodes. Doping PZT thin films with Nb (PNZT) improves imprint behavior of LSCO//PZT//LSCO capacitors considerably. We have demonstrated that PNZT 4/30/70 // LSCO capacitors thermally processed at either 550{degrees}C or 675{degrees}C have almost identical initial hysteresis properties and exhibit essentially no fatigue out to approximately 10{sup 10} cycles.
This paper describes a method for criticality control at fissile material storage facilities. The method involves the use criticiality indices for storage canisters. The logic, methodology, and results for selected canisters are presented. A concept for an interactive computer program using the method is also introduced. The computer program can be used in real time (using precalulated data) to select a Criticality Index (CI) for a container when it is delivered to or packaged at a site. Criticality safety is assured by controlling the sum of the CIs at each storage location below a defined Emit value when containers are moved.
The possibility of worker exposure to radioactive materials during accidents at nuclear facilities is a principal concern of the DOE. The KBERT software has been developed at Sandia National Laboratories under DOE support to address this issue by assisting in the estimation of risks posed by accidents at chemical and nuclear facilities. KBERT is an acronym for Knowledge-Based system for Estimating hazards of Radioactive material release Transients. The current prototype version of KBERT focuses on calculation of doses and consequences to in-facility workers due to accidental releases of radioactivity. This report gives detailed instructions on how a user who is familiar with the design, layout and potential hazards of a facility can use KBERT to assess the risks to workers in that facility. KBERT is a tool that allows a user to simulate possible accidents and observe the predicted consequences. Potential applications of KBERT include the evaluation of the efficacy of evacuation practices, worker shielding, personal protection equipment and the containment of hazardous materials.
An Image Compression and Authentication Module (ICAM) has been designed to perform the digitization, compression, and authentication of video images in a camera enclosure. The ICAM makes it possible to build video surveillance systems that protect the transmission and storage of video images. The ICAM functions with both NTSC 525 line and PAL 625 line cameras and contains a neuron chip (integrated circuit) permitting it to be interfaced with a local operating network which is part of the Modular Integrated Monitor System (MIMS). The MIMS can be used to send commands to the ICAM from a central controller or any sensor on the network. The ICAM is capable of working as a stand alone unit or it can be integrated into a network of other cameras. As a stand alone unit it sends its video images directly over a high speed serial digital link to a central controller for storage. A number of ICAMs can be multiplexed on a single coaxial cable. In this case, images are captured by each ICAM and held until the MIMS delivers commands for an individual image to be transmitted for review or storage. The ICAM can capture images on a time interval basis or upon receipt of a trigger signal from another sensor on the network. An ICAM which collects images based on other sensor signals, forms the basis of an intelligent {open_quotes}front end{close_quotes} image collection system. The burden of image review associated with present video systems is reduced by only recording the images with significant action. The cards used in the ICAM can also be used to decompress and display the compressed images on a NTSC/PAL monitor.
Coatings produced by feeding a steel wire into a high-velocity oxy-fuel (HVOF) torch are being intensively studied by the automotive industry as a cost-effective alternative to the more expensive cast iron sleeves currently used in aluminum engine blocks. The microstructure and properties of the sprayed coatings and the overall economics of the process depend critically on the melting and atomization occurring at the wire tip. This paper presents results characterizing several aspects of wire melting and droplet breakup in an HVOF device. Fluctuations in the incandescent emission of the plume one centimeter downstream from the wire tip were recorded using a fast photodiode. A Fourier transform of the light traces provided a measure of the stripping rate of molten material from the wire tip. Simultaneous in-flight measurement of atomized particle size and velocity distributions were made using a Phase Doppler Particle Analyzer (PDPA). The recorded size distributions approximate a log-normal distribution. Small particles traveled faster than large particles, but the difference was considerably smaller than simple aerodynamic drag arguments would suggest. A set of experiments was carried out to determine the effect that variations in torch gas flow rates have on wire melt rate, average particle size, and average particle velocity. The observed variation of particle size with spray condition is qualitatively consistent with a Weber breakup of the droplets coming off the wire. The measurements also showed that it was possible to significantly alter atomized particle size and velocity without appreciably changing the wire melt rate.
This paper discusses two commercially-available laser diagnostics that have been used in thermal spray research at Sandia National Laboratories: (1) a Phase Doppler Particle Analyzer (PDPA) and (2) a Laser Two-Focus (L2F) velocimeter. The PDPA provides simultaneous, correlated measurements of particle velocity and particle size distributions; but, particle sizing doesn`t work well with non-spherical particles or particles with rough surfaces. The L2F is used to collect particle velocity and number density distributions, and it can readily distinguish and separately measure particles with off-axis velocity vectors. PDPA and L2F principles of operation are presented along with potential advantages and limitations for thermal spray research. Four experiments were conducted to validate and compare measurement results with the PDPA and L2F instruments: (1) spinning wire, (2) powder in a High-Velocity Oxy-Fuel (HVOF) jet, (3) powder in a cold jet, and (4) droplets in a wire-fed HVOF jet. TWO DIFFERENT TYPES of commercially-available laser velocimeter systems, a Phase Doppler Particle Analyzer and a Laser-Two-Focus velocimeter have been used in the Thermal Spray Research Laboratory at Sandia National Laboratories. Each of these techniques has inherent advantages and limitations for thermal spray, and each involves assumptions that may not be valid for some experimental conditions. This paper describes operating principles and possible sources of measurement error for these two diagnostic systems. Some potential advantages and limitations are also presented. Four types of experiments were also conducted to validate and compare PDPA and L2F measurement results: (1) spinning wire, (2) powder in a High-Velocity Oxy-Fuel (HVOF) jet, (3) powder in a cold jet, and (4) droplets in a wire-fed HVOF jet. We also offer a few observations related to practical issues such as ease-of-use, reliability, and effects of dust and vibration in a thermal spray lab.
In the context of U.S. and Russian lab-to-lab initiatives, Sandia National Laboratories contracted with Kurchatov Institute Russian Research Center to demonstrate the feasibility of remotely monitoring the storage of nuclear material. The cooperative experiment was to demonstrate the Remote Monitoring System (RMS) with a minimum of 10 kg of HEU in storage at reciprocal facilities. The Kurchatov Institute selected a site at their facility and the DOE selected a site at the Argonne National Laboratory-West facility. At Kurchatov, there is material for monitoring in a floor vault, a cabinet, and shipping containers. At Argonne West, material stored in two types of storage systems is available for material monitoring. This paper discusses the system concept from both perspectives: the operator of a facility where a RMS is deployed and the user of the RMS at the remote site. The demonstration provides a unique opportunity to have a bilateral demonstration/evaluation where each participant examines all aspects of the system. The hardware and software needed to implement this system is discussed. The impacts to the operation of the facilities are discussed as well as the use of the system to remotely monitor a facility. This technology provides the capability of remotely monitoring the access to the stored nuclear materials but is not a real time security alarm system. Several enhancements to the Remote Monitoring System have been identified for future consideration.
The MIMS program is funded by the Department of Energy under the Office of Nonproliferation and National Security. The program objective is to develop cost effective, modular, multi-sensor monitoring systems. Both in-plant and ground based sensors are envisioned. It is also desirable to develop sensors/systems that can be fielded/deployed in a rapid fashion. A MIMS architecture was selected to allow modular integration of sensors and systems and is based on LonWorks technology, commercially developed by Echelon Corporation. The first MIMS fieldable hardware was demonstrated at Lawrence Livermore National Laboratory. The field test, known within the DOE as the Item Tracking and Transparency (IT&I) demonstration, involved the collaboration and cooperation of five DOE laboratories (Sandia (SNL), Lawrence Livermore (LLNL), Pacific Northwest (PNL), Los Alamos (LANL), and Oak Ridge (ORNL)). The IT&T demonstration involved the monitoring of special nuclear material as it was transported around the facility utilizing sensors from the participating labs. The scenario was programmed to ignore normal activity in the facility until entry into the room where the material was stored. A second demonstration, which involved three separate scenarios, was conducted at Idaho National Engineering Laboratory (INEL). The participants included representatives from SNL, LLNL, PNL, and INEL. DOE has selected INEL as the long term testbed for MIMS developed sensors, systems, and scenarios. This paper will describe the installation, intended purpose, and results of the field demonstrations at LLNL and INEL under the MIMS program.
A nonaqueous coprecipitation process has been developed to prepare controlled stoichiometry lithium manganese oxalate precipitates. The process involved mixing a methanolic Li-Mn nitrate solution with a methanolic solution containing tetramethylammonium oxalate as the precipitating agent. The resulting oxalates were readily converted to a variety of phase pure lithium manganese oxides at moderate temperatures ({le}600{degrees}C), where the phase formed was determined by the initial Li/Mn ratio in the starting solution. Metal cation dopants have been incorporated into the oxalate precipitate by dissolving the appropriate metal nitrate in the Li-Mn precursor solution The various starting solutions, oxalate precipitates, and calcined oxides have been extensively characterized using a variety of techniques, including {sup 7}Li NMR, TGA/DTA, SEM, and XRD. Results indicate that a strong interaction occurs between Li and Mn in the nitrate solution which carries over into the oxalate phase during precipitation. The morphology and the crystallite size of the oxide powders were shown to be controlled by the morphology of the oxalate precursor and the oxalate calcination temperature, respectively. The results of initial cathode performance tests with respect to dopant type (Al, Ni, Co) and concentration for LiMn{sub 2}O{sub 4} are also reported.
The Treaty on Open Skies has very specific requirements as a confidence building measure, but it could also serve as a component of an SNM Cutoff monitoring strategy. The participants to the Treaty are European countries, the United States, and Canada and would have to be extended to include other than the present signatories if it were to be used in a worldwide SNM verification Cutoff role. The major nuclear powers with the exception of China are signatories to the Treaty and the inclusion of other member states will only be considered once entry into force has started. The technology and data sharing provisions of the Treaty have defined the airborne sensor performance specifications. Therefore, the Treaty allowed sensor technology may not be adequate for the purposes of monitoring an SNM Cutoff regime. New sensors and sensor performance levels to adequately monitor an SNM Cutoff regime may be proposed only after entry into force of the Treaty on Open Skies. The utility of an aerial inspection component to the monitoring strategy for an SNM Cutoff regime would best be evaluated with field trials using realistic scenarios. This would allow the testing of synergism among other components of an overall monitoring strategy and would lend insight into the appropriate sensor technology to be recommended for future implementation.
While many techniques exist for production of soft tooling, for die casting there is limited recent experience with cast tooling. The most common US alloy used for manufacture of die casting tooling is wrought AISI H13. If the performance of the cast material is comparable to the wrought counterpart, the use of investment cast HI 3 tooling directly from patterns made via rapid prototyping is of considerable interest. A metallurgical study of investment cast H13 was conducted to evaluate the mechanical behavior in simulated die casting applications. Variable thickness plate investment castings of AISI H13 hot work die steel were produced and characterized in the as-cast and heat-treated conditions. The characterization included light microscopy and mechanical testing. Wrought samples of standard and premium grade H13 were heat-treated and characterized similarly for comparison. Microstructural differences were observed in as-cast samples produced in different section thicknesses. Dendrite cell size and carbide morphology constituted the most prominent microstructural differences observed. After a full heat-treatment, microstructural differences between the wrought material and cast materials were slight regardless of section thickness.The mechanical properties of the cast and heat-treated material proved similar to the properties of the standard heat-treated wrought material. A thermal fatigue testing unit was to con-elate the heat checking susceptibility of H13 steel to its processing and consequent microstructural condition. Surface hardness decreased significantly with thermal cycling, and heat checking was observed in as few as 50 cycles. Thermal softening and thermal fatigue susceptibility were quantified and discussed relative to the microstructural conditions created by processing and heat-treatment. It was found that the premium grade wrought H13 steel provided the best overall resistance to heat checking.
Changes in the reactant ion composition in the ion mobility spectrometer (IMS) can result in a change in the ionization processes occurring in the ionization region, ultimately leading to an altered instrumental response for the analyte, and exacerbating the problem of qualitative and quantitative analysis. Some species are very susceptible to changes in reactant ions, while other species are relatively unaffected. These types of behavior are observed for two common explosives, namely, hexahydro-1,3,5-trinitrol,3,5-triazine (RDX) and 1,3,5-trinitrotoluene (TNT), respectively. To control the reactant ion composition, and hence the gas phase chemistry, it is necessary to control the composition of gases present in the ionization region of the IMS. A series of modifications are described for the PCP Phemto-Chem 100 IMS that afford the requisite control. The effectiveness of these modifications for analysis of RDX and TNT are described and contrasted with that observed for the unmodified system.
Sputter deposition of ZnS:Mn/SrS:Ce multilayered broad-band ``white`` emission thin film electroluminescent (TFEL) stacks has been investigated. To date, deposition of these multilayers has been limited to vacuum evaporation techniques and atomic layer epitaxy, both of which require two different substrate temperatures for growth of high quality ZnS and SrS. This repeated thermal cycling during multilayer deposition can induce stress, defects, and interdiffusion with adversely affect EL performance. Sputter deposition of ZnS and SrS produces high quality TFELs for a wider range of substrate temperatures. Both materials can be sputter deposited at a common temperature (300-350{degrees}C) which eliminates the need for thermal cycling and increases manufacturability. Luminance outputs from sputter deposited ZnS and SrS thin films are comparable to those from evaporated films, making sputtering an attractive alternative deposition technique for these materials. We report on the effects of sputter deposition parameters including chamber pressure, substrate temperature, and H2S process gas partial pressure on the resultant composition and morphology of ZnS:Mn and SrS:Ce thin films and multilayers. Their EL performance was evaluated and correlated to composition and morphology.
This paper presents an overview of physical protection cooperation activities between Sandia (SNL) and the Former Soviet Union (FSU) regarding Material Protection Control and Accounting (MPC&A) responsibilities. Begun four years ago as part of the Safe, Secure Dismantlement Program, this project is intended to stem proliferation of weapons of mass destruction. Purpose of the program is to accelerate progress toward a goal shared by both Russia and the United States: to reduce the risk of nuclear weapons proliferation, including such threats as theft, diversion, and unauthorized possession of nuclear materials. This will be accomplished by strengthening the MPC&A systems in both, countries. This new program (US Department of Energy Laboratory-to-Laboratory MPC&A program) is designed to complement Government-to-Government programs sponsored by US Senators Nunn and Lugar. US and Russian representatives exchange visits and discuss physical protection philosophies. Russian representatives have received formal training in the US process of system design and analysis to include the design of an effective physical protection system, determination of physical protection system objectives, initial design of a physical protection system, evaluation of the design, and often redesign or refinement of the existing system. Some Russian organizations have philosophies similar to those of the United States, but when they differ, the US and Russian representatives must negotiate. Other Russian organizations, because of heavy reliance on guard forces, have not developed a systematic design process. Cooperative work between US national laboratories and Russian counterparts has resulted in major physical protection enhancements at a Russian demonstration site and other advancements for Laboratory-to-Laboratory projects.
The objective of this project is to develop novel catalysts for the direct conversion of natural gas to a liquid fuel. The current work investigates the use of biomimetic metalloporphyrins as catalysts for the partial oxidation of light alkanes to alcohols.
Long term mechanical creep and fatigue testing at elevated temperatures requires reliable systems with safeguards to prevent destruction of equipment, loss of data and negative environmental impacts. Toward this goal, a computer controlled system has been developed and built for interlocking tests run on elevated temperature mechanical test facilities. Sensors for water flow, water pressure, water leakage, temperature, power and hydraulic status are monitored to control specimen heating equipment through solid state relays and water solenoid valves. The system is designed to work with the default interlocks present in the RF generators and mechanical tests systems. Digital hardware consists of two National Instruments 1/0 boards mounted in a Macintosh IIci computer. Software is written in National Instruments LabVIEW. Systems interlocked include two MTS closed loop servo controlled hydraulic test frames, one with an RF generator and one with both an RF generator and a quartz lamp furnace. Control for individual test systems is modularized making the addition of more systems simple. If any of the supporting utilities fail during tests, heating systems, chill water and hydraulics are powered down, minimizing specimen damage and eliminating equipment damage. The interlock control is powered by an uninterruptible power supply. Upon failure the cause is documented in an ASCII file.
This document describes the processes to be used for creating corporate information systems within the scope of the Integrated information Services (IIS) Center. This issue A describes the Analysis and Implementation phases within the context of the entire life cycle. Appendix A includes a full set of examples of the analysis set deliverables. Subsequent issues will describe the other life cycle processes as we move toward enterprise-level management of information assets, including information meta-models and an integrated corporate information model. The analysis phase as described here, when combined with a specifications repository, will provide the basis for future reusable components and improve traceability of information system specifications to enterprise business rules.
In an R&D environment, Environmentally Conscious Manufacturing (ECM), which focuses on specific materials processing and manufacturing operations, can be used to bring about a broader objective: pollution prevention. Decreasing the impact a product or process has on the environment is quickly becoming the way to do business. In the past, the impact on the environment was considered separately from manufacturing processes. Now, companies are beginning to see the benefits of designing to minimize environmental impact. Incorporating upfront the process changes that reduce environmental impact offers improved process efficiency and long-term cost savings not only for manufacturing operations but also for R&D. Among the approaches used, all with the same objective of decreasing pollution and environmental impact from manufacturing or other business operations, are Environmentally Conscious Manufacturing (ECM), Design for Environment (DfE), and Pollution Prevention (P2).
The upwind leapfrog scheme for electromagnetic scattering is briefly described. Its application to the 3D Maxwell`s time domain equations is shown in detail. The scheme`s use of upwind characteristic variables and a narrow stencil result in a smaller demand in communication overhead, making it ideal for implementation on distributed memory parallel computers. The algorithm`s implementation on two message passing computers, a 1024-processor nCUBE 2 and a 1840-processor Intel Paragon, is described. Performance evaluation demonstrates that the scheme performs well with both good scaling qualities and high efficiencies on these machines.
We report on the optical and electrical characterization of aromatic, fluorinated, fully imidized, organic soluble, thermally and photochemically, crosslinkable, guest-host polyimides for integrated optics. Refractive indices and optical losses were measured to evaluate the performance of these materials for passive applications. Materials were doped with two high temperature nonlinear optical chromophores, and poled during crosslinking to produce nonlinear optical materials. Measurements of electro-optic coefficient, macroscopic second order susceptibility, and conductivity were performed to assess these materials as potential candidates for active devices.
Numerical simulations of dynamic uniaxial strain loading of fiber-reinforced composites are presented that illustrate the wide range of deformation mechanisms that can be captured using a micromechanics-based homogenization technique as the material model in existing continuum mechanics computer programs. Enhancements to the material model incorporate high strain-rate plastic response, elastic nonlinearity, and rate-dependent strength degradation due to material damage, fiber debonding, and delamination. These make the model relevant to designing composite structural components for crash safety, armor, and munitions applications.
Different solderability tests have been developed to determine the wetting behavior of solder on metallic surfaces. None offer an exact measure of capillary flow associated with conventional mixed technology soldering. With shrinking package designs, increasing reliability requirements, and the emergence of new soldering technologies, there is a growing need to better understand and predict the flow of solder on printed wiring board (PWB) surfaces. Sandia National Laboratories has developed a capillary flow solderability test, through a joint effort with the National Center for Manufacturing Sciences, that considers this fundamental wetting issue for surface mount technology. The test geometry consists of a metal strip (width, {delta}) connected to a circular metal pad (radius, r{sub c}). Test methodology, experimental results, and validation of a flow model are presented in this paper.
Streak camera based diagnostics are vital to the inertial confinement fusion program at Sandia National Laboratories. Performance characteristics of various readout systems coupled to an EGG-AVO streak camera were analyzed and compared to scaling estimates. The purpose of the work was to determine the limits of the streak camera performance and the optimal fielding conditions for the Amador Valley Operations (AVO) streak camera systems. The authors measured streak camera limitations in spatial resolution and sensitivity. Streak camera limits on spatial resolution are greater than 18 lp/mm at 4% contrast. However, it will be difficult to make use of any resolution greater than this because of high spatial frequency variation in the photocathode sensitivity. They have measured a signal to noise of 3,000 with 0.3 mW/cm{sup 2} of 830 nm light at a 10 ns/mm sweep speed. They have compared lens coupling systems with and without micro-channel plate intensifiers and systems using film or charge coupled device (CCD) readout. There were no conditions where film was found to be an improvement over the CCD readout. Systems utilizing a CCD readout without an intensifier have comparable resolution, for these source sizes and at a nominal cost in signal to noise of 3, over those with an intensifier. Estimates of the signal-to-noise for different light coupling methods show how performance can be improved.
In July, 1994, a team of materials specialists from Sandia and U S Industry traveled to Russia and the Ukraine to select and fund projects in materials and process technology in support of the Newly Independent States/Industrial Partnering Program (NIS/IPP). All of the projects are collaborations with scientists and Engineers at NIS Institutes. Each project is scheduled to last one year, and the deliverables are formatted to supply US Industry with information which will enable rational decisions to be made regarding the commercial value of these technologies. This work is an unedited interim compilation of the deliverables received to date.
This report summarizes a Sandia program that included partnerships with Lawrence Livermore National Laboratory and Synthetica Technologies, Inc. to design and test a steam reforming system for treating Hanford underground storage tank (UST) wastes. The benefits of steam reforming the wastes include the resolution of tank safety issues and improved radionuclide separations. Steam reforming destroys organic materials by first gasifying, then reacting them with high temperature steam. Tests indicate that up to 99% of the organics could be removed from the UST wastes by steam exposure. In addition, it was shown that nitrates in the wastes could be destroyed by steam exposure if they were first distributed as a thin layer on a surface. High purity alumina and nickel alloys were shown to be good candidates for materials to be used in the severe environment associated with steam reforming the highly alkaline, high nitrate content wastes. Work was performed on designing, building, and demonstrating components of a 0.5 gallon per minute (gpm) system suitable for radioactive waste treatment. Scale-up of the unit to 20 gpm was also considered and is feasible. Finally, process demonstrations conducted on non-radioactive waste surrogates were carried out, including a successful demonstration of the technology at the 0.1 gpm scale.
A methodology for risk management in the design of software systems is presented. It spans security, safety, and correct operation of software within the context of its environment, and produces a risk analysis and documented risk management strategy. It is designed to be iteratively applied, to attain appropriate levels of detail throughout the analysis. The methodology and supporting tools are discussed. The methodology is critiqued relative to other research in the field. Some sample applications of the methodology are presented.
As a result of a number of events the inventory of fissile materials no longer in nuclear weapons in the United States is increasing. This has led to a growing concern regarding the potential for theft and/or diversion and accountability of this material. Straight-Line is a project whose purpose is to demonstrate a site-independent system to monitor stored nuclear material (e.g. plutonium) and integrate the collection, processing and dissemination of information regarding this material. Safeguards and security (S&S) goals of this project include data transfer of information on nuclear material to appropriate users to enhance S&S, continuous on-line accountability, reduction of hands-on access to nuclear materials, incorporation of information security technologies, and early detection of tampering or unauthorized material movement. This paper addresses threat considerations, S&S requirements, S&S objectives, and issues for the Straight-Line project. S&S features and benefits of this project are discussed with respect to existing item monitoring systems and/or other material tracking systems being developed.
There are several distinctive types of coring-induced fractures that can be recognized in core on the basis of morphology, assisted by certain characteristics such as edge effects and surface ornamentation. The shape and orientation of many of these induced fractures offer information on the in-situ stress conditions and the coring process. Petal, petal-centerline, scribe-knife, disc, and torque-related fractures may all be caused by coring in vertical wells. Saddle fractures, (related to petal fractures) are unique to horizontal core, as is the polishing of fracture surfaces during coring. other features such as scribe-line rotation, hammer marks, and rotary-bit patterns are important in making correct interpretations of the in situ stress and reservoir permeability, and in making the maximum use of the evidence bearing on reservoir fracture-system permeability provided by both induced and natural fractures.
Sandia National Laboratories Annular Core Research Reactor (ACRR) is undertaking a new mission for the Department of Energy: production of the radioisotope {sup 99}Mo used in nuclear medicine applications. Isotope production is significantly different from previous programs conducted at the ACRR that typically required high intensity, short duration pulses. The current UO{sub 2}-BeO fuel will power the initial startup phase of the production program, and can perform exceptionally well for this mission. However, this type of fuel is no longer available, commercially or otherwise. This paper presents the results of some preliminary studies of commercially available fuels.
Formal interactions with Kurchatov Institute (KI) began summer 1994 on material protection, control and accountability (MPC&A). Contracts were placed by LANL and Sandia with KI to implement a nuclear material accounting system and a physical security system at a KI demonstration facility which contain two critical assemblies with special nuclear material. LLNL implemented May 1995 a task to measure by gamma-ray spectroscopy the uranium enrichment of fuel in the facility. This laboratory-to-laboratory effort is part of the cooperative program between US and Russian institutes in nuclear material nonproliferation. In 1994-5, KI personnel demonstrated the physical security system. The next facility for work in MPC&A at KI is the Central Storage Facility, which is important for the computerized material accounting system for KI.
EcoSys is an environmental decision support tool to assist in the design of green products and process. EcoSys consist of an information and expert system that contains input from experts in products, processes and the environment as well as a flexible, goal driven, rule based decision model that can accommodate many environmental management perspectives. This includes allowing specific users to specify weighting factors for the impact decision model. This tool is extensible in that it can be utilized within the boundaries of a company and migrated to include suppliers and customers until full life cycles are assessed. We discussed the details and use of the environmental models available for the experts. We also showed how interviews with manufacturing experts led to the design of a goal-driven rule based reasoning system to support the problem solving. Finally, we offered a number of examples that detailed the types of analysis possible with EcoSys. Our ongoing work is to increase the precision of the environmental attributes database and to extend the product-process database to support a wider set of product analyses. Based on user feedback, we are also continuing to improve the X-Window user interface.
Three sets of rock samples have been subjected to planar impact to characterize loading, Hugoniot and release responses. A slate form Pennsylvania was tested over the stress range of 5 GPa to 140 GPa. Phyllite from the Lupin Mine (Canada) was tested over the 14--50 GPa stress region. Finally, granite samples from the SHIST test site (New Mexico) were tested over the 10--20 GPa stress region. The granite tests included a transmitted-wave experiment at about 10 GPa. In 12 of the 13 tests, a reverse-ballistic configuration (optimized for Hugoniot and release measurements) was used. The remaining test (conducted on the granite) provided a transmitted waveform from which precursor, Hugoniot and release properties were obtained. Velocity interferometry (VISAR) was used as the primary diagnostic throughout. The slate data showed an unexpected inflection downward in the Hugoniot at around 8 GPa. The slate and granite showed release paths lying below the Hugoniot for lower stress levels (below {approx} 60 GPa), while the slate release paths were ``normal`` (above the Hugoniot) at higher stress levels. In addition, the granite releases were found to lie substantially below the Hugoniot in the 30--40 GPa region; this may be related to the quartz-stishovite transition. The present results are generally consistent with earlier work.
We report on experimental measurements and numerical predictions of shear-induced migration of particles in concentrated suspensions subjected to flow in the wide gap between a rotating inner cylinder placed eccentrically within a fixed outer cylinder (a cylindrical bearing). The suspensions consists of large, noncolloidal spherical particles suspended in a viscous Newtonian liquid. Nuclear magnetic resonance (NMR) imaging is used to measure the time evolution of concentration and velocity profiles as the flow induced particle migration from the initial, well-mixed state. A model originally proposed by Phillips et al. (1992) is generalized to two dimensions. The coupled equations of motion and particle migration are solved numerically using an explicit pseudo-transient finite volume formulation. While not all of the qualitative features observed in the experiments are reproduced by this general numerical implementation, the velocity predictions show moderately good agreement with the experimental data.
Prototype circuit board test vehicles wee assembled with three candidate lead-free solders: 96.5Sn-3.5Ag (wt %), 58Bi-42Sn, and 91.84Sn-3.33 Ag 83Bi., using a forced-convection/infrared furnace and RMA flux based pastes. Wettability of circuit board features and packages was best with Sn-Ag-Bi alloy followed in order by Bi-Sn and Sn-Ag solders. The Sn-Ag-Bi solder had a greater propensity for void formation in the joints. The reliability assessment was based upon solder joint microstructure and the shear strength of selected leadless packages. Solder joint damage was of a greater extent after thermal shock exposures rather than thermal cycling. The Sn-Ag-Bi alloy on the largest package appeared most susceptible to thermal shock. Test vehicle performance clearly demonstrated that, with the non-lead solders, local thermal expansion mismatch can be as detrimental to joint integrity as the traditional global mismatch damage.
The manufacturing feasibility and attachment reliability of a series of newly developed lead-free solders were investigated for wave soldering applications. Some of the key assembly aspects addressed included: wettability as a function of board surface finish, flux activation and surface tension of the molten solder, solder joint fillet quality and optimization of soldering thermal profiles. Generally, all new solder formulations exhibited adequate wave soldering performance and can be considered as possible alternatives to eutectic SnPb for wave soldering applications. Further process optimization and flux development is necessary to achieve the defect levels associated with the conventional SnPb process.
Variable thickness plate investment castings of AISI H13 hot work die steel were pour and characterized in the as-cast and heat treated conditions. The characterization included light microscopy and mechanical testing. Wrought samples of standard and premium grade H13 steel were heat treated and characterized similarly for comparison. Microstructural differences were observed in as-cast samples poured to different section thicknesses. Dendrite cell size and carbide morphology constituted the most prominent microstructural differences observed. After a full heat treatment, however, Microstructural differences between the wrought material and cast materials were slight regardless of section thickness. The mechanical properties of the cast and heat treated material proved similar to the properties of the standard heat treated wrought material. A thermal fatigue testing unit was designed and built to correlate the heat checking susceptibility of AISI H13 steel to its processing and consequent microstructural condition. Surface hardness decreased significantly with thermal cycling, and heat checking was noticed in as few as 50 cycles. Thermal softening and thermal fatigue susceptibility were quantified and discussed relative to the microstructural conditions created by processing and heat treatment. It was found that the premium grade wrought H13 steel provided the best overall resistance to heat checking; however, the heat-treat cast and as-cast H13 tool steel (made from standard grade wrought H13 tool steel) provided comparable resistance to heat checking in terms Of area fraction of heat checking and maximum crack length.
Verification of a video image has been a major problem for safeguards for several years. Various verification schemes have been tried on analog video signals ever since the mid-1970`s. These schemes have provided a measure of protection but have never been widely adopted. The development of reasonably priced complex video processing integrated circuits makes it possible to digitize a video image and then compress the resulting digital file into a smaller file without noticeable loss of resolution. Authentication and/or encryption algorithms can be more easily applied to digital video files that have been compressed. The compressed video files require less time for algorithm processing and image transmission. An important safeguards application for authenticated, compressed, digital video images is in unattended video surveillance systems and remote monitoring systems. The use of digital images in the surveillance system makes it possible to develop remote monitoring systems that send images over narrow bandwidth channels such as the common telephone line. This paper discusses the video compression process, authentication algorithm, and data format selected to transmit and store the authenticated images.
The Swedish Nuclear Power Inspectorate (SKI) and the US Department of Energy (DOE) sponsored work on a Remote Monitoring System (RMS) that was installed in August 1994 at the Barseback Works north of Malmo, Sweden. The RMS was designed to test the front end detection concept that would be used for unattended remote monitoring activities. Front end detection reduces the number of video images recorded and provides additional sensor verification of facility operations. The function of any safeguards Containment and Surveillance (C/S) system is to collect information which primarily is images that verify the operations at a nuclear facility. Barseback is ideal to test the concept of front end detection since most activities of safeguards interest is movement of spent fuel which occurs once a year. The RMS at Barseback uses a network of nodes to collect data from microwave motion detectors placed to detect the entrance and exit of spent fuel casks through a hatch. A video system using digital compression collects digital images and stores them on a hard drive and a digital optical disk. Data and images from the storage area are remotely monitored via telephone from Stockholm, Sweden and Albuquerque, NM, USA. These remote monitoring stations operated by SKI and SNL respectively, can retrieve data and images from the RMS computer at the Barseback Facility. The data and images are encrypted before transmission. This paper presents details of the RMS and test results of this approach to front end detection of safeguard activities.
June 1993, the A-PRIMED project (Agile Product Realization of electrMEchanical Devices) was formed with a concurrent engineering team of product designers, analysts, CNC machinists, robotic assembly scientists, electronics communications developers, statisticians and human factors scientists at Sandia National Laboratories, to develop and demonstrate a process for a much faster design-to-production cycle for precision electromechanical devices. The team had to develop the culture and infrastructure to support communications between remotely located members, as well as demonstrate a shortened cycle time made possible by developing new technologies. These new technologies were then adopted by the team and introduced to their work partners to support new work processes. By March 1995, the A-PRIMED team has used the new technologies and work processes to design and build qualified new products in only 24 days.
Sorption of iodide (I{sup {minus}}) on cinnabar (HgS) and chalcocite (Cu{sub 2}S) was examined as a function of pH at 25{degrees}C in a series of batch experiments. Calculated distribution ratios (K{sub d}) far exceed those reported for other minerals; maximal K{sub d}`s of 1375 cc/g (Cu{sub 2}S) and 3080 c/g (HgS) were observed between pH 4-5, but wre substantial at all pH`s measured (4 < pH < 10). Iodide sorption apparently occurs by the formation of an insoluble surface solid solution with exposed Hg and Cu sites. Surface solid solution formation is favored at low pH due to the lessened electrostatic repulsion of the iodide ion by the sulfide surfaces.
A numerical solution for buoyant natural convection within a square enclosure containing a fluid with highly temperature dependent viscosity is presented. Although the fluid properties employed do not represent any real fluid, the large variation in the fluid viscosity with temperature is characteristic of turbulent flow modeling with eddy-viscosity concepts. Results are obtained using a primitive variable formulation and the resistor method. The results presented include velocity, temperature and pressure distributions within the enclosure as well as shear stress and heat flux distributions along the enclosure walls. Three mesh refinements were employed and uncertainty values are suggested for the final mesh refinement. These solutions are part of a contributed benchmark solution set for the subject problem.
The isotope {sup 99}Mo would be produced at Sandia using ACRR and the collocated Hot Cell Facility. {sup 99}Mo would be produced by irradiating targets coated with {sup 235}U in the form of highly enriched U{sub 3}O{sub 8}; after 7 days, the target would be removed and the isotope extracted using the Cintichem process. The Monte Carlo neutronics computer code MCNP was used to determine the optimum configuration for production, using various fractions of the US demand. Although ACRR operates at a low power level, the US demand for {sup 99}Mo can be easily met using a reasonable number of targets.
Techniques for characterizing density gradients generated during typical powder compaction processes are reviewed and several are evaluated. The techniques reviewed are ultrasonic velocity measurements, laser ultrasonic velocity measurements, x-ray radiography, autoradiography, computer tomography (CT), magnetic resonance imaging (MRI), and simple image analysis of polished cross-sections. Experimental results are reported for all of these techniques except autoradiography, CT and MRI. The test specimens examined were right circular cylinders of a high length/diameter ratio (to ensure significant density variation) pressed from commercial spray-dried alumina powders. Although the density gradients could be detected with all four techniques, ultrasonic velocity measurements gave the best contour map of gradients and is therefore most suitable for model validation. On the other hand, it was concluded that x-ray radiography is preferable in situations where cost and/or number of samples are more important that high resolution.
Bimodal space reactor systems provide both thermal propulsion for the spacecraft orbital transfer and electrical power to the spacecraft bus once it is on station. These systems have the potential to increase both the available payload in high energy orbits and the available power to that payload. These increased mass and power capabilities can be used to either reduce mission cost by permitting the use of smaller launch vehicles or to provide increased mission performance from the current launch vehicle. A major barrier to the deployment of these bimodal systems has been the cost associated with their development. This paper describes a bimodal spacecraft bus with performance potential to permit more than 70% of the instrumented payload of the Titan IV/Centaur to be launched from the Atlas IIAS. The development cost is minimized by basing the design on existing component technologies.
Smokes are frequently used as visual obscurants in access delay applications. A new generation of low temperature pyrotechnic smokes is being developed. Terephthalic Acid (TPA) smoke was developed by the U.S. Army and Sebacic Acid (SA) smoke is being developed by Thiokol Corp. The advantages these smokes offer over traditional pyrotechnic smokes include; low generation temperature (approximately 450{degree}C), lower toxicity, and lower corrosivity. The low generation temperature reduces smoke layering effects and allows the addition of sensory irritants, such as o-Chlorobenzylidene Malononitrile (CS), to the formulation. Some advantages low temperature pyrotechnic smokes offer over nonpyrotechnic smokes include; low cost, simplicity, compactness, light weight, long storage life, and orientation insensitive operation. Low cost permits distribution of multiple units for reduced vulnerability and refill flexibility. Some disadvantages may include the combustibility of the smoke particulate; however, the published lower explosive limit of the mentioned materials is approximately ten times greater than the concentration required for effective obscuration. The TPA smoke cloud contains small quantities of benzene, formaldehyde, and carbon monoxide; no benzene or formaldehyde was identified during preliminary SA smoke analyses performed by Thiokol Corp. Sandia performed tests and analyses on TPA smoke to determine the smoke cloud composition, the quantity of particulate produced per canister, and the relationship between airborne particulate concentration and measured optical density values. Current activities include characterization of SA smoke.
Because of the low humidity environments required in the fabrication of nuclear explosives, assembly technicians can be charged to tens of kilovolts while operating, for example, compressed air, venturi-type, `explosion proof` vacuum cleaners. Nuclear explosives must be isolated from all sources of, and return paths for, AC power and from any part of the lightning protection system. This requirement precludes the use of static ground conductors to drain any charge accumulations. Accordingly, an experimental study of the basic charging mechanisms associated with vacuum operations were identified, the charge generation efficacies of various commercial cleaners were established, and a simple method for neutralizing the charge was devised.
Polymeric silica sols, were deposited on commercial {gamma}-alumina supports to prepare gas separation membranes. Optimization of the sol fractal dimension and radius of gyration and minimization of condensation rate led to formation of a discrete film with pores of molecular dimensions. Two coatings of this sol (A2{sup **}) led to a membrane with ideal separation factor of 7 for helium versus nitrogen after calcination to 400C (helium permeance 0.002 cm{sup 3}/cm{sup 2}-s-cm Hg). Partial sintering of these membranes resulted in a further reduction in pore size or narrowing of pore size distribution as evidenced by larger separation factors e.g. 9 for helium versus nitrogen (helium permeance 0.0028 cm{sup 3}/cm{sup 2}-s-cm Hg) with only one A2{sup **} coating. Single gas measurements also showed high ideal separation factors for helium versus methane, propylene, sulfur hexafluoride and carbon dioxide. The deposited A2{sup **} membrane was reacted with titanium isopropoxide (Ti(O i-Pr){sub 4}) to improve both its thermal and chemical stability and modify its pore size. This reaction led to an increase in the membrane selectivity to >300 for He versus N{sub 2} below to 120C, and CO{sub 2} versus CH{sub 4}, when measured below 200C. A2{sup **} was also used as a host matrix for preparing imogolite composite membranes that showed molecular sieving behavior.
The aluminum alloy process implemented in Sandia`s Photovoltaic Device Fabrication Laboratory (PDFL) has major beneficial effects on the performance of commercial multicrystalline-silicon (mc-Si) substrates. Careful analysis of identically processed cells (except for the alloyed layer) in matched mc-Si substrates clearly indicates that the majority of the benefit arises from improved bulk minority carrier diffusion length. Based on spectral response measurements and PC-1D modeling the authors have observed improvements due to the alloy process of up to 400% in the average diffusion length in moderate-area cells and around 50% in large-area cells. The diffusion length is dramatically improved in the interior of the silicon grains in alloyed substrates, resulting in the majority of the recombination occurring at the grain boundaries and localized areas with high defect densities.
The Department of Energy is conducting an ongoing investigation of the consequences of taking fuel burnup into account in the design of spent fuel transportation packages. A series of experiments, collectively called the Spent Fuel Safety Experiment (SFSX), has been devised to provide integral benchmarks for testing computer-generated predictions of spent fuel behavior. A set of experiments is planned in which sections of unirradiated fuel rods are interchanged with similar sections of spent PWR fuel rods in a critical assembly. By determining the critical size of the arrays, one can obtain benchmark data for comparison with criticality safety calculations. The integral reactivity worth of the spent fuel can be assessed by comparing the measured delayed critical fuel loading with and without spent fuel. An analytical effort to model the experiments and anticipate the core loadings required to yield the delayed critical conditions runs in parallel with the experimental effort.
During the January 1994 Summit Presidents Clinton and Yeltsin agreed on the goal of ensuring the ``transparency and irreversibility`` of the nuclear arms reduction process. As a result, negotiations are presently underway between the United States Government and the Russian Federation to confirm the stockpiles of plutonium and highly enriched uranium removed from nuclear weapons. In December 1994 the United States presented a paper to the Russian Federation proposing additional measures to provide broader transparency of nuclear arms reduction. The US Department of Energy is studying the implementation of these broader transparency measures at appropriate DOE facilities. The results of the studies include draft protocols for implementation, assessments of the implementation procedures and the impacts on the facilities and estimates of the cost to implement these measures at various facilities.
Under the Department of Energy (DOE)/United States Air Force (USAF) Memorandum of Understanding, a system is being designed that will use high pressure carbon dioxide for the separation of oils, greases, and solvents from non-hazardous solid waste. The contaminants are dissolved into the high pressure carbon dioxide and precipitated out upon depressurization. The carbon dioxide solvent can then be recycled for continued use. Excellent extraction capability for common manufacturing oils, greases, and solvents has been measured. It has been observed that extraction performance follows the dilution model if a constant flow system is used. The solvents tested are extremely soluble and have been extracted to 100% under both liquid and mild supercritical carbon dioxide conditions. These data are being used to design a 200 liter extraction system.
The widely dispersed, unmanned launch facilities (LFs) for land-based ICBMs (intercontinental ballistic missiles) currently do not have visual assessment capability for existing intrusion alarms. The security response force currently must assess each alarm on-site. Remote assessment will enhance manpower, safety, and security efforts. Sandia National Laboratories was tasked by the USAF Electronic Systems Center to research, recommend, and demonstrate a cost-effective remote video assessment capability at missile LFs. The project`s charter was to provide: system concepts; market survey analysis; technology search recommendations; and operational hardware demonstrations for remote video assessment from a missile LF to a remote security center via a cost-effective transmission medium and without using visible, on-site lighting. The technical challenges of this project were to: analyze various video transmission media and emphasize using the existing missile system copper line which can be as long as 30 miles; accentuate and extremely low-cost system because of the many sites requiring system installation; integrate the video assessment system with the current LF alarm system; and provide video assessment at the remote sites with non-visible lighting.
The WIPP Disposal Room Model (DRM) is a numerical model with three major components constitutive models of TRU waste, crushed salt backfill, and intact halite -- and several secondary components, including air gap elements, slidelines, and assumptions on symmetry and geometry. A sensitivity analysis of the Disposal Room Model was initiated on two of the three major components (waste and backfill models) and on several secondary components as a group. The immediate goal of this component sensitivity analysis (Phase I) was to sort (rank) model parameters in terms of their relative importance to model response so that a Monte Carlo analysis on a reduced set of DRM parameters could be performed under Phase II. The goal of the Phase II analysis will be to develop a probabilistic definition of a disposal room porosity surface (porosity, gas volume, time) that could be used in WIPP Performance Assessment analyses. This report documents a literature survey which quantifies the relative importance of the secondary room components to room closure, a differential analysis of the creep consolidation model and definition of a follow-up Monte Carlo analysis of the model, and an analysis and refitting of the waste component data on which a volumetric plasticity model of TRU drum waste is based. A summary, evaluation of progress, and recommendations for future work conclude the report.
This paper presents a survey of technologies useful in providing early warning in physical security systems. Early warning is important in virtually all types of security systems whether they are used for temporary (tactical, portable, or semi-permanent) applications, border warning, fixed-site detection, or standoff surveillance detection. With the exception of the standoff surveillance detection systems, all systems discussed in this paper usually involve a moving target. The fact that a person(s) to be detected in a standoff surveillance scenario is not moving presents challenging problems and requires different applications of technology. The technologies commonly used to detect moving targets and some suggestions for detection of stationary targets are addressed in this paper.
The Department of Energy`s Office of Fissile Material Disposition (FMD) is analyzing long-term storage and disposition options for surplus weapons-usable fissile materials, preparing a programmatic environmental impact statement (PEIS), preparing for a record of decision (ROD) regarding this material and conducting other activities. The primary security objectives of this program are to reduce major security risks and strengthen arms reduction and nonproliferation (NP). To help achieve these objectives, a safeguards and security (S&S) team consisting of participants from Sandia, Los Alamos, and Lawrence Livermore National Laboratories was established. The S&S activity for this program is a cross-cutting task which addresses all of the FMD program options. It includes both domestic and international safeguards and includes areas such as physical protection, nuclear materials accountability and material containment and surveillance. This paper will discuss the activities of the Fissile Materials Disposition Program (FMDP) S&S team as well as some specific S&S issues associated with various FMDP options/facilities. Some of the items to be discussed include the threat, S&S requirements, S&S criteria for assessing risk, S&S issues concerning fissile material processing/facilities, and international and domestic safeguards.
An experimental investigation into active control of bending vibrations in thick bar and plate-like structural elements is described. This work is motivated by vibration problems in machine tools and photolithography machines that require greater control authority than available from conventional surface mounted PZT patches or PVDF films. Focus of this experiment is a cantilevered circular steel bar in which PZT stacks are mounted in cutouts near the bar root. Axially aligned and offset from the neutral axis, these actuators control the bending vibrations by generating moments in the bar through their compressive loads. A Positive Feedback control law is used to significantly augment the damping in the first bending mode. Implications of the experimental results for machine tool stability enhancement are discussed.
Photonic device activities at Sandia National Laboratories are founded on an extensive materials research program that has expanded to include device development, and an applications focus that heavily emphasizes communications and interconnects. The resulting program spans a full range of photonics research, development, and applications projects, from materials synthesis and device fabrication to packaging, test, and subsystem development. The heart of this effort is the Compound Semiconductor Research Laboratory which was established in 1988 to bring together device and materials research and development to support Sandia`s role in weapons technologies. This paper presents an overview of Sandia`s photonics program and its directions, using three communications-based applications as examples.
Sandia is developing a Personnel and Material Tracking System (PAMTRAK) which uses a variety of techniques to monitor material inside a vault in real-time. It can detect material movement using video cameras inside the vault or motion sensors attached to the material. It also contains two prototype attribute monitoring systems that continuously measure material weight, temperature or movement. A site can use any of these alone or together to extend physical inventory intervals. PAMTRAK can reduce the cost of storing material by reducing inventory frequency and radiation exposure to workers. Analysis at Savannah River in 1992 estimated that installing PAMTRAK in the 7 active and future vaults at that site would save $1,073,000 per year by reducing inventory frequency from monthly to yearly. Performing similar calculations now, assuming lower radiation exposure limits of 700m Rem per year, new inventory reduction guidelines allowing a baseline interval of 6 months, and an achieved inventory interval of 3 years, results in an estimated average savings of $400,000 per year. PAMTRAK, since it is real-time, can detect theft or diversion soon enough to give the guard force a chance of recovering the material and apprehending the perpetrator. In performing an inventory a site typically checks only a fraction of the material using random, statistical sampling, while PAMTRAK monitors all material in the vault. In addition to static environments such as vaults, PAMTRAK can be used to protect material in active work areas. Several of the sensor types can ignore activity around material but still report alarms if the material is moved or handled. PAMTRAK includes a personnel tracking capability that allows a site to monitor and restrict personnel movements. It can exclude workers from designated areas unless they have explicit permission to be there. It can also enforce the 2-person rule by requiring a worker to be accompanied by at least one other qualified worker.
When software is used in safety-critical, security-critical, or mission-critical situations, it is imperative to understand and manage the risks involved. A risk assessment methodology and toolset have been developed which are specific to software systems. This paper describes the concepts of the methodology, with emphasis on the experience of designing a toolset to support the methodology. Also presented are results of applying the methodology to two real software-based products: the software toolset itself, and a network firewall.
This glossary was prepared in fulfillment of the Glossary Preparation Task identified in the Program Plan for providing Assistance to the Russian Federation in Nuclear Material Control and Accounting and Physical Protection. The Program Plan is part of the Cooperative Threat Reduction Program as provided for under House Resolution (H.R.) 3807 (Title II, as referenced under Public Law (P.L.) 102-229. The terms in this glossary were derived from physical protection training material prepared at Sandia. The training material, and thus refinements to the glossary, has undergone years of development in presentation to both domestic and international audiences. Also, Russian Colleagues and interpreters have reviewed the translations for accuracy.
A method of determining the dynamic operating cost benefits of energy storage systems for utility applications is presented. The production costing program DYNASTORE is used to analyze economic benefits for ``utility B,`` an isolated island utility, using heuristic unit commitment algorithms. The unit commitment is done using chronologic load data and a detailed model of the utility characteristics. Several unit commitment scenarios are run for utility B, and the results are presented. Comparisons between various Battery Energy Storage System (BESS) applications, as well as cases with and without battery storage, are shown. Results show that for utility B, a BESS of 300 MW size used for either load leveling or spinning reserve provides the greatest economic benefit.
An investigation was made into the effect of microstructure on the peak toughness and shape of the crack growth resistance curves for two ceramic-metal composites. An Al{sup 2}O{sup 3}/Al composite formed by Reactive Metal Penetration was used along with an AlN/Al composite formed using a reactive infiltration technique. The results indicate that the toughness increases with an increase in the volume fraction of the metal phase for a particular composite composition, and the peak toughness and shape of the R-Curve also depend on the composite microstructure and metal composition.
Data are presented from the Air Intake Shaft Test, an in situ test fielded at the Waste Isolation Pilot Plant (WIPP). The construction of this shaft, well after the initial three access shafts, presented an unusual opportunity to obtain valuable detailed data on the mechanical response of a shaft for application to seal design. These data include selected fielding information, test configuration, instrumentation activities, and comprehensive results from a large number of gages. Construction of the test began in December 1987; gage data in this report cover the period from May 1988 through July 1995, with the bulk of the data obtained after obtaining access in November, 1989 and from the heavily instrumented period after remote gage installation between May, 1990, and October, 1991.
Experiences as an environmental activist have produced some insights into addressing the current public over-reaction to environmental risks, and in particular to the risks posed by nuclear industry development.
This overview presents current research at Sandia National Laboratories in the Virtual Reality and Intelligent Simulation Lab. Into an existing distributed VR environment which we have been developing, and which provides shared immersion for multiple users, we are adding virtual actor support. The virtual actor support we are adding to this environment is intended to provide semi-autonomous actors, with oversight and high-level guiding control by a director/user, and to allow the overall action to be driven by a scenario. We present an overview of the environment into which our virtual actors will be added in Section 3, and discuss the direction of the Virtual Actor research itself in Section 4. We will briefly review related work in Section 2. First however we need to place the research in the context of what motivates it. The motivation for our construction of this environment, and the line of research associated with it, is based on a long-term program of providing support, through simulation, for situational training, by which we mean a type of training in which students learn to handle multiple situations or scenarios. In these situations, the student may encounter events ranging from the routine occurance to the rare emergency. Indeed, the appeal of such training systems is that they could allow the student to experience and develop effective responses for situations they would otherwise have no opportunity to practice, until they happened to encounter an actual occurance. Examples of the type of students for this kind of training would be security forces or emergency response forces. An example of the type of training scenario we would like to support is given in Section 4.2.
MicroDexterity Systems Inc. and Sandia National Laboratories are collaborating on the design of a six degree-of-freedom surgeon-controlled micropositioner and a six degree-of-freedom surgeon-controlled master for use in microsurgery. A control system will provide the linkage between the force-reflecting master and micropositioner for force scaling, position scaling, and tremor filtering. The technologies developed by this project are expected to enhance the skills of surgeons, improve the success rates for existing microsurgical procedures, make new high-dexterity procedures possible, and ultimately reduce surgical costs by increasing the precision and speed of operations. This paper discusses the motivation, approach, and accomplishments to date.
We report a new application of atomic force microscopy (AFM) for process characterization of GaAs integrated circuit fabrication. By using the near atomic-level z-resolution of AFM, we are able to gain information not available by other imaging techniques in a number of steps in the sequence for GaAs IC fabrication. A nondestructive method of determining whether micron-sized vias have been etched to completion is presented. In addition, the AFM has been used to evaluate material removal following several of fabrication steps. Shallow trench formation occurs as a result of GaAs removal during the sidewall etch for a commonly used sidewall spacer process. This effect has been not been observed previously by other techniques. Other examples of unintentional removal of small amounts of GaAs during shallow wet and dry etches are presented. These examples show the utility of AFM as an in-line process characterization tool.
This report evaluates telerobotic and teleoperational arm-based retrieval systems that require advanced robotic controls. These systems will be deployed in waste retrieval activities in Hanford`s Single Shell Tanks (SSTs). The report assumes that arm-based, retrieval systems will combine a teleoperational arm and control system enhanced by a number of advanced and telerobotic controls. The report describes many possible enhancements, spanning the full range of the control spectrum with the potential for technical maturation. The enhancements considered present a variety of choices and factors including: the enhancements to be included in the actual control system, safety, detailed task analyses, human factors, cost-benefit ratios, and availability and maturity of technology. Because the actual system will be designed by an offsite vendor, the procurement specifications must have the flexibility to allow bidders to propose a broad range of ideas, yet build in enough restrictions to filter out infeasible and undesirable approaches. At the same time they must allow selection of a technically promising proposal. Based on a preliminary analysis of the waste retrieval task, and considering factors such as operator limitations and the current state of robotics technology, the authors recommend a set of enhancements that will (1) allow the system to complete its waste retrieval mission, and (2) enable future upgrades in response to changing mission needs and technological advances.
Most neutron spectrum determination methodologies ignore self-shielding effects in dosimetry foils and treat covers with an exponential attenuation model. This work provides a quantitative analysis of the approximations in this approach. It also provides a methodology for improving the fidelity of the treatment of the dosimetry sensor response to a level consistent with the user`s spectrum characterization approach. A library of correction functions for the energy-dependent sensor response has been compiled that addresses dosimetry foils/configurations in use at the Sandia National Laboratories Radiation Metrology Laboratory.
We introduce an up-scaled, buoyant invasion percolation model (UIP) for application to non-wetting, dense, non-aqueous phase liquid (DNAPL) migration at the geologic formation scale within the saturated zone of an aquifer. The UEP model incorporates a gravitational potential to model the displacement of fluids of different densities and can be used for either LNAPLs (lighter than water) or DNAPLs (denser than water). We demonstrate model behavior in a simulated braided stream deposit. Simulations show the influence of textural changes across layers and gravity forces in controlling DNAPL migration. While our results are encouraging, the application of this up-scaled percolation model requires a series of tests both in the laboratory and in the field before judgment of sufficient validity for its intended purpose is achieved.
Initiated in 1991; the Dish/Stirling Joint Venture Program (DSJVP) is a 5-year, $17.2 million joint venture which is funded by Cummins Power Generation, Inc. (CPG) of Columbus, Indiana and the United States Department of Energy`s (DOE) Solar Thermal and Biomass Power Division. Sandia National Laboratories administers and provides technical management for this contract on the DOE`s behalf. In January, 1995; CPG advanced to Phase 3 of this three-phase contract. The objective of the DSJVP is to develop and commercialize a 7-kW. Dish/Stirling System for remote power markets by 1997. In this paper, the technical status of the major subsystems which comprise the CPG 7-kW{sub e} Dish/Stirling System is presented. These subsystems include the solar concentrator, heat pipe receiver, engine/alternator, power conditioning, and automatic controls.
The report describes a preliminary evaluation of models for transforming regional climate model output from a regional to a local scale for the Yucca Mountain area. Evaluation and analysis of both empirical and numerical modeling are discussed which is aimed at providing site-specific, climate-based information for use by interfacing activities. Two semiempirical approaches are recommended for further analysis.
A mathematical formulation is presented for describing the transport of air, water and energy through porous media. The development follows a continuum mechanics approach. The theory assumes the existence of various average macroscopic variables which describe the state of the system. Balance equations for mass and energy are formulated in terms of these macroscopic variables. The system is supplemented with constitutive equations relating fluxes to the state variables, and with transport property specifications. Specification of various mixing rules and thermodynamic relations completes the system of equations. A numerical simulation scheme, employing the method of lines, is described for one-dimensional flow. The numerical method is demonstrated on sample problems involving nonisothermal flow of air and water. The implementation is verified by comparison with existing numerical solutions.
Measurements of capillary barrier performance have been conducted in above-grade wooden structures (boxes) configured to measure the water balance. The capillary-barrier portion of the boxes is 6.0 m long, 2.0 m wide, and 1.2 m high with a slope of 5%. A coarse-grained material was placed in the bottom 25-cm of the box with a 90-cm deep fine-grained material (local soil) on top. A region for laterally diverted water to accumulate and drain was created in the last 1.0 m of the box. The soil at the top is terraced into five, 1.4 m long, level intervals to prevent runoff when adding water. Water is added uniformly to the entire top of the box at a rate of about 66 l/day, or an infiltration rate of 1.7 m/year. The top of the box is covered with fiber-reinforced plastic to minimize evaporation of water, discourage plant growth, and prevent rainfall from contacting the soil. Five drains are spaced along the bottom of the coarse layer. These drains discretize the coarse layer into five collection regions to provide a means of identifying the breakthrough location into the coarse layer. A drain is also located in the downdip collection region of the box. Soil moisture changes were measured in the fine-grained material with a frequency-domain reflectometry (FDR) probe, which was calibrated using soil from the field site at a known moisture content and density.
The objective of Sandia`s refining of coal-derived liquids project is to determine the relationship between hydrotreating conditions and Product characteristics. The coal-derived liquids used in this work were produced In HTI`s first proof-of-concept run using Illinois No. 8 coal. Samples of the whole coal liquid product, distillate fractions of this liquid, and Criterion HDN-60 catalyst were obtained from Southwest Research Inc. Hydrotreating experiments were performed using a continuous operation, unattended, microflow reactor system. A factorial experimental design with three variables (temperature, (310{degrees}C to 388{degrees}C), liquid hourly space velocity (1 to 3 g/h/cm{sup 3}(cat)), pressure (500 to 1000 psig H{sub 2}) is being used in this project. Sulfur and nitrogen contents of the hydrotreated products were monitored during the hydrotreating experiments to ensure that activity was lined out at each set of reaction conditions. Results of hydrotreating the whole coal liquid showed that nitrogen values in the products ranged from 549 ppM at 320{degrees}C, 3 g/h/cm{sup 3}(cat), 500 psig H{sub 2} to <15 ppM at 400{degrees}C, 1 g/h/ cm{sup 3}(cat), 1000 psig H{sub 2}.
A laboratory investigation has been carried out to determine the effects of elevated temperature and stress on the creep deformation of welded tuffs recovered from Busted Butte in the vicinity of Yucca Mountain, Nevada. Water saturated specimens of tuff from thermal/mechanical unit TSw2 were tested in creep at a confining pressure of 5.0 MPa, a pore pressure of 4.5 MPa, and temperatures of 25 and 250 C. At each stress level the load was held constant for a minimum of 2.5 {times} 10{sup 5} seconds and for as long as 1.8 {times} 10{sup 6} seconds. One specimen was tested at a single stress of 80 MPa and a temperature of 250 C. The sample failed after a short time. Subsequent experiments were initiated with an initial differential stress of 50 or 60 MPa; the stress was then increased in 10 MPa increments until failure. The data showed that creep deformation occurred in the form of time-dependent axial and radial strains, particularly beyond 90% of the unconfined, quasi-static fracture strength. There was little dilatancy associated with the deformation of the welded tuff at stresses below 90% of the fracture strength. Insufficient data have been collected in this preliminary study to determine the relationship between temperature, stress, creep deformation to failure, and total failure time at a fixed creep stress.
This report discusses the testing and evaluation of thirteen commercially available exterior digital video motion detection (VMD) systems. The systems were evaluated for use in a specific outdoor application. The report focuses primarily on the testing parameters, each system`s advertised features, and the nuisance alarm and detection test results.
Bridged polysilsesquioxanes represent an interesting family of hybrid organic-inorganic composite materials. It has been shown that manipulation of the organic bridging component offers the potential for the synthesis of a variety of materials with a range of surface areas and porosities. In addition, incorporation of a heteroatom within the bridging organic component allows for further chemical transformation of the polysilsesquioxane material.
This paper presents the relations that describe thermodynamic equilibrium in a three-phase system. Multiple components, including air, water, and oil components, are considered in three phases: (1) aqueous, (2) oil, and (3) gas. Primary variables are specified for each of seven possible phase combinations. These primary variables are then used to determine the necessary secondary variables to completely describe the system. Criteria are also developed to check the stability of each phase configuration and determine possible transitions from one phase configuration to another phase configuration via phase appearances and disappearances.
The authors analyze the problem of radiation trapping (imprisonment) by the method of Holstein. The process is described by an integrodifferential equation which shows that the effective radiative decay rate of the system depends on the size and the shape of the active medium. Holstein obtains a global decay rate for a particular geometry by assuming that the radiating excited species evolves into a steady state spatial mode. The authors derive a new approximation for the trapped decay which has a space dependent decay rate and is easy to implement in a detailed computer simulation of a plasma confined within an arbitrary geometry. They analyze the line shapes that are relevant to a near-atmospheric-pressure mixture of He and Xe. This line-shape analysis can be utilized in either the Holstein formulae or the space-dependent decay approximation.
Polyelectrolyte (PE) gels are swollen polymer/solvent networks that undergo a reversible volume collapse/expansion through various types of stimulation. Applications that could exploit this large deformation and solvent expulsion/absorption characteristics include robotic {open_quotes}fingers{close_quotes} and drug delivery systems. The goals of the research were to first explore the feasibility of using the PE gels as {open_quotes}smart materials{close_quotes} - materials whose response can be controlled by an external stimulus through a feedback mechanism. Then develop a predictive capability to simulate the dynamic behavior of these gels. This involved experimentally characterizing the response of well-characterized gels to an applied electric field and other stimuli to develop an understanding of the underlying mechanisms which cause the volume collapse. Lastly, the numerical analysis tool was used to simulate various potential engineering devices based on PE gels. This report discusses the pursuit of those goals through experimental and computational means.
Reactor-scale ex-vessel boiling experiments were performed in the CYBL facility at Sandia National Laboratories. The boiling flow pattern outside the RPV bottom head shows a center pulsating region and an outer steady two-phase boundary layer region. The local heat transfer data can be correlated in terms of a modified Rohsenow correlation.
In some nuclear reactor core melt accidents, a potential exists for molten core debris to be dispersed into the containment under high pressure. Resulting energy transfer to the containment atmosphere can pressurize the containment. This process, known as direct containment heating (DCH), has been the subject of extensive experimental and analytical programs sponsored by the US Nuclear Regulatory Commission (NRC). DCH modeling has been a major focus for the development of the CONTAIN code. In support of the peer review, extensive analyses of DCH experiments were performed in order to assess the CONTAIN code`s DCH models and improve understanding of DCH phenomenology. The present paper summarizes this assessment effort.
This study assessed the impact of aging on the performance and reliability of active fire protection systems including both fixed fire suppression and fixed fire detection systems. The experience base shows that most nuclear power plants have an aggressive maintenance and testing program and are finding degraded fire protection system components before a failure occurs. Also, from the data reviewed it is clear that the risk impact of fire protection system aging is low. However, it is assumed that a more aggressive maintenance and testing program involving preventive diagnostics may reduce the risk impact even further.
The Environmental Restoration (ER) Project has been tasked with the characterization, assessment, remediation and long-term monitoring of contaminated waste sites at Sandia National Laboratories/New Mexico (SNL/NM). Many of these sites will require remediation which will involve the use of baseline technologies, innovative technologies that are currently under development, and new methods which will be developed in the near future. The Technology Applications Program (TAP) supports the ER Project and is responsible for development of new technologies for use at the contaminated waste sites, including technologies that will be used for remediation and restoration of these sites. The purpose of this report is to define the remediation needs of the ER Project and to identify those remediation needs for which the baseline technologies and the current development efforts are inadequate. The area between the remediation needs and the existing baseline/innovative technology base represents a technology gap which must be filled in order to remediate contaminated waste sites at SNL/NM economically and efficiently. In the first part of this report, the remediation needs of the ER Project are defined by both the ER Project task leaders and by TAP personnel. The next section outlines the baseline technologies, including EPA defined Best Demonstrated Available Technologies (BDATs), that are applicable at SNL/NM ER sites. This is followed by recommendations of innovative technologies that are currently being developed that may also be applicable at SNL/NM ER sites. Finally, the gap between the existing baseline/innovative technology base and the remediation needs is identified. This technology gap will help define the future direction of technology development for the ER Project.
A telephone survey was conducted to evaluate the quality of service provided to the primary customers of the Corporate Ergonomics Group (CEG). One hundred clients who received services between October 1993 and June 1994 were asked questions on their expectations, implementation of ergonomic recommendations, follow-ups, time required, productivity improvements, symptom alleviation, and satisfaction. Suggestions on how processes could be improved were also solicited. In general, recommendations are being implemented, worksite evaluations are going smoothly, and customers are satisfied with the process. The CEG was pleased to learn that half of the people who implemented recommendations experienced improvements in productivity, and four out of five symptomatic customers experienced partial or complete relief. Through analysis of the data and by studying clients` suggestions for process improvement, the CEG has developed a strategy for changing and improving current procedures and practices. These plans can be found in the last section of this report.
The SERAPBIM (SEgmented RAil PHased Induction Motor) concept is a linear induction motor concept which uses rapidly-pulsed magnetic fields and a segmented reaction rail, as opposed to low-frequency fields and continuous reaction rails found in conventional linear induction motors. These improvements give a high-traction, compact, and efficient linear motor that has potential for advanced high speed rail propulsion. In the SERAPBIM concept, coils on the vehicle push against a segmented aluminum rail, which is mounted on the road bed. Current is pulsed as the coils cross an edge of the segmented rail, inducing surface currents which repel the coil. The coils must be pulsed in synchronization with the movement by reaction rail segments. This is provided by a sense-and-fire circuit that controls the pulsing of the power modulators. Experiments were conducted to demonstrate the feasibility of the pulsed induction motor and to collect data that could be used for scaling calculations. A 14.4 kg aluminum plate was accelerated down a 4 m track to speeds of over 15 m/sec with peak thrust up to 18 kN per coilset. For a trainset capable of 200 mph speed, the SERAPHIM concept design is based on coils which are each capable of producing up to 3.5 kN thrust, and 30 coil pairs are mounted on each power car. Two power cars, one at each end of the train, provide 6 MW from two gas turbine prime power units. The thrust is about 210.000 N and is essentially constant up to 200 km/hr since wheel slippage does not limit thrust as with conventional wheeled propulsion. A key component of the SERAPHIM concept is the use of passive wheel-on-rah support for the high speed vehicle. Standard steel wheels are capable of handling over 200 mph. The SERAPHIM cost is comparable to that for steel-wheel high-speed rail, and about 10% to 25% of the projected costs for a comparable Maglev system.
The Vital Issues Process, developed by the Sandia National Laboratories Strategic Technologies Department, was utilized by the Health Care Task Force Advisory Group to apply structure to their policy deliberations. By convening three expert panels, an overarching goal for the New Mexico health care system, seven desired outcomes, nine policy options, and 17 action items were developed for the New Mexico health care system. Three broadly stated evaluation criteria were articulated and used to produce relative rankings of the desired outcomes and policy options for preventive care and information systems. Reports summarizing the policy deliberations were submitted for consideration by the Health Care Task Force, a Joint Interim Committee of the New Mexico Legislature, charged with facilitating the development and implementation of a comprehensive health care delivery system for New Mexico. The Task Force reported its findings and recommendations to the Second Session of the 41st New Mexico State Legislature in January 1994.
The Automated Assembly Team of the APRIMED Project (abbreviated as A{prime}) consists of two parts: the Archimedes Project, which is an ongoing project developing automated assembly technology, and the A{prime} Robot Team. Archimedes is a second generation assembly planning system that both provides a general high-level assembly sequencing capability and, for a smaller class of products, facilitates automatic programming of a robotic workcell to assemble them. The A{prime} robot team designed, developed, and implemented a flexible robot workcell which served as the automated factory of the A{prime} project. In this document we briefly describe the role of automated assembly planning in agile manufacturing, and specifically describe the contributions of the Archimedes project and the A{prime} robot team to the A{prime} project. We introduce the concepts of the Archimedes automated assembly planning project, and discuss the enhancements to Archimedes which were developed in response to the needs of the A{prime} project. We also present the work of the A{prime} robot team in designing and developing the A{prime} robot workcell, including all tooling and programming to support assembly of the A{prime} discriminator devices. Finally, we discuss the process changes which these technologies have enabled in the A{prime} project.
This is a preliminary report of a multi-year collaboration of the authors addressing the subject: Can a facility be designed for team learning and would it improve the efficiency and effectiveness of team interactions? Team learning in this context is a broad definition that covers all activities where small to large groups of people come together to work, to learn, and to share through team activities. Multimedia, networking, such as World Wide Web and other tools, are greatly enhancing the capability of individual learning. This paper addresses the application of technology and design to facilitate group or team learning. Many organizational meetings need tens of people to come together to do work as a large group and then divide into smaller subgroups of five to ten to work and then to return and report and interact with the larger group. Current facilities were not, in general, designed for this type of meeting. Problems with current facilities are defined and a preliminary design solution to many of the identified problems is presented.
The results of previously completed vertical outcrop sampling transacts are summarized with respect to planning downhole sampling. The summary includes statistical descriptions and descriptions of the spatial variability of the sampled parameters. Descriptions are made on each individual transect, each thermal/mechanical unit and each previously defined geohydrologic unit. Correlations between parameters indicate that saturated hydraulic conductivity is not globally correlated to porosity. The correlation between porosity and saturated hydraulic conductivity is both spatially and lithologically dependent. Currently, there are not enough saturated hydraulic conductivity and sorptivity data to define relationships between these properties and porosity on a unit by unit basis. Also, the Prow Pass member of the Crater Flat Tuff and stratigraphically lower units have gone essentially unsampled in these outcrop transacts. The vertical correlation length for hydrologic properties is not constant across the area of the transacts. The average sample spacing within the transacts ranges from 1.25 to 2.1 meters. It appears that, with the exception of the Topopah Spring member units, a comparable sample spacing will give adequate results in the downhole sampling campaign even with the nonstationarity of the vertical correlation. The properties within the thermal/mechanical units and geohydrologic units of the Topopah Spring member appear to have a spatial correlation range less than or equal to the current sample spacing within these units. For the downhole sampling, a sample spacing of less than 1.0 meters may be necessary within these units.
This report describes the first practical, non-invasive technique for detecting and imaging currents internal to operating integrated circuits (ICs). This technique is based on magnetic force microscopy and was developed under Sandia National Laboratories` LDRD (Laboratory Directed Research and Development) program during FY 93 and FY 94. LDRD funds were also used to explore a related technique, charge force microscopy, for voltage probing of ICs. This report describes the technical work performed under this LDRD as well as the outcomes of the project in terms of publications and awards, intellectual property and licensing, synergistic work, potential future work, hiring of additional permanent staff, and benefits to DOE`s defense programs (DP).
Sandia National Laboratories has established a Cooperative Research and Development Agreement with consortium members of the National Center for Manufacturing Sciences (NCMS) to develop fundamental generic technology in the area of printed wiring board materials and surface finishes. Improved solderability of copper substrates is an important component of the Sandia-NCMS program. We are investigating the effects of surface roughness on the wettability and solderability behavior of several different types of copper board finishes. In this paper, we present roughness and solderability characterizations for a variety of chemically-etched copper substrates. Initial testing on six chemical etches demonstrate that surface roughness can be greatly enhanced through chemical etching. Noticeable improvements in solder wettability were observed to accompany increases in roughness. A number of different algorithms and measures of roughness were used to gain insight into surface morphologies that lead to improved solderability.