Polysilicon surface-micromachining is a Micro-Electro-Mechanical Systems (MEMS) manufacturing technology where the infrastructure for manufacturing silicon integrated circuits is used to fabricate micro-miniature mechanical devices. This presentation describes a multi-level mechanical polysilicon surface-micromachining technology and includes a discussion of the issues which affect device manufacture and performance. The multi-level technology was developed and is employed primarily to fabricate microactuated mechanisms. The intricate and complex motion offered by these devices is naturally accompanied by various forms of fraction and wear in addition to the classical stiction phenomena associated with micromechanical device fabrication and usage.
The National Energy Modeling System (NEMS) developed by the U.S. Department of Energy`s Energy Information Administration is a well-recognized model that is used to project the potential impact of new electric generation technologies. The NEMS model does not presently have the capability to model energy storage on the national grid. The scope of this study was to assess the feasibility of, and make recommendations for, the modeling of battery energy storage systems in the Electricity Market of the NEMS. Incorporating storage within the NEMS will allow the national benefits of storage technologies to be evaluated.
At the request of the U.S. Department of Energy, Office of Geothermal Technologies, Sandia National Laboratories convened a group of drilling experts in Berkeley, CA, on April 15-16, 1997, to discuss advanced geothermal drilling systems. The objective of the workshop was to develop one or more conceptual designs for an advanced geothermal drilling system that meets all of the criteria necessary to drill a model geothermal well. The drilling process was divided into ten essential functions. Each function was examined, and discussions were held on the conventional methods used to accomplish each function and the problems commonly encountered. Alternative methods of performing each function were then listed and evaluated by the group. Alternative methods considered feasible or at least worth further investigation were identified, while methods considered impractical or not potentially cost-saving were eliminated from further discussion. This report summarizes the recommendations of the workshop participants. For each of the ten functions, the conventional methods, common problems, and recommended alternative technologies and methods are listed. Each recommended alternative is discussed, and a description is given of the process by which this information will be used by the U.S. DOE to develop an advanced geothermal drilling research program.
A program for evaluating packaging components that may be used in transporting mixed-waste forms has been developed and the first phase has been completed. This effort involved the screening of ten plastic materials in four simulant mixed-waste types. These plastics were butadiene-acrylonitrile copolymer rubber, cross-linked polyethylene (XLPE), epichlorohydrin rubber, ethylene-propylene rubber (EPDM), fluorocarbon (Viton or Kel-F), polytetrafluoroethylene, high-density polyethylene (HDPE), isobutylene-isoprene copolymer rubber (butyl), polypropylene, and styrene-butadiene rubber (SBR). The selected simulant mixed wastes were (1) an aqueous alkaline mixture of sodium nitrate and sodium nitrite; (2) a chlorinated hydrocarbon mixture; (3) a simulant liquid scintillation fluid; and (4) a mixture of ketones. The testing protocol involved exposing the respective materials to 286,000 rads of gamma radiation followed by 14-day exposures to the waste types at 60{degrees}C. The seal materials were tested using vapor transport rate (VTR) measurements while the liner materials were tested using specific gravity as a metric. For these tests, a screening criterion of 0.9 g/hr/m{sup 2} for VTR and a specific gravity change of 10% was used. Based on this work, it was concluded that while all seal materials passed exposure to the aqueous simulant mixed waste, EPDM and SBR had the lowest VTRs. In the chlorinated hydrocarbon simulant mixed waste, only Viton passed the screening tests. In both the simulant scintillation fluid mixed waste and the ketone mixture simulant mixed waste, none of the seal materials met the screening criteria. For specific gravity testing of liner materials, the data showed that while all materials with the exception of polypropylene passed the screening criteria, Kel-F, HDPE, and XLPE offered the greatest resistance to the combination of radiation and chemicals.
This paper presents an overview of the methodology used in the recent performance assessment (PA) to support the U.S. Department of Energy (DOE) Carlsbad Area Office`s (CAO`s) Waste Isolation Pilot Plant (WIPP) Compliance Certification Application (CCA). The results of this recently completed WIPP PA will be presented. Major release modes contributing to the total radionuclide release to the accessible environment will be discussed. Comparison of the mean complementary cumulative distribution function (CCDF) curve against the Environmental Protection Agency (EPA) radionuclide release limits will be presented.
The Department of Energy submitted a Compliance Certification Application for the Waste Isolation Pilot Plant to the Environmental Protection Agency (EPA) in October, 1996. A critical part of this application was a Performance Assessment which predicts the cumulative radioactive release to the accessible environment over a time period of 10,000 years. Comparison of this predicted release to the EPA standard shows a comfortable margin of compliance. The scientific understanding that was critical to developing this assessment spans a broad range of geotechnical disciplines, and required a thorough understanding of the site`s geology and hydrology. Evaluation of the geologic processes which are active in the site region establishes that there will be no natural breach of site integrity for millions of years, far longer than the 10,000 year regulatory period. Inadvertent human intrusion is, therefore, the only credible scenario to lead to potential radioactive release to the accessible environment. To substantiate this conclusion and to quantify these potential releases from human intrusion, it has been necessary to develop an understanding of the following processes: (1) salt creep and shaft seal efficacy; (2) gas generation from organic decomposition of waste materials and anoxic corrosion of metals in the waste and waste packages; (3) solubilities for actinides in brine; (4) fluid flow in Salado formation rocks, and (5) hydrologic transport of actinides in the overlying dolomite aquifers. Other issues which had to be evaluated to allow definition of breach scenarios were brine reservoir occurrences and their associated reservoir parameters, consequences of mining over the repository, and drilling for natural resources in the vicinity of the repository. Results of all these studies will be briefly summarized in this paper.
Many research activities in subsurface transport require the numerical simulation of multiphase flow in porous media. This capability is critical to research in environmental remediation (e.g. contaminations with dense, non-aqueous-phase liquids), nuclear waste management, reservoir engineering, and to the assessment of the future availability of groundwater in many parts of the world. This paper presents an unstructured grid numerical algorithm for subsurface transport in heterogeneous porous media implemented for use on massively parallel (MP) computers. The mathematical model considers nonisothermal two-phase (liquid/gas) flow, including capillary pressure effects, binary diffusion in the gas phase, conductive, latent, and sensible heat transport. The Galerkin finite element method is used for spatial discretization, and temporal integration is accomplished via a predictor/corrector scheme. Message-passing and domain decomposition techniques are used for implementing a scalable algorithm for distributed memory parallel computers. Illustrative applications are shown to demonstrate capabilities and performance, one of which is modeling hydrothermal transport at the Yucca Mountain site for a radioactive waste facility.
Adaptive numerical methods offer greater efficiency than traditional numerical methods by concentrating computational effort in regions of the problem domain where the solution is difficult to obtain. In this paper, the authors describe progress toward adding mesh refinement to MPSalsa, a computer program developed at Sandia National laboratories to solve coupled three-dimensional fluid flow and detailed reaction chemistry systems for modeling chemically reacting flow on large-scale parallel computers. Data structures that support refinement and dynamic load-balancing are discussed. Results using uniform refinement with mesh sequencing to improve convergence to steady-state solutions are also presented. Three examples are presented: a lid driven cavity, a thermal convection flow, and a tilted chemical vapor deposition reactor.
Wind-energy researchers at Sandia National Laboratories (SNL) and the National Renewable Energy Laboratory (NREL) are developing a new, light-weight, modular system capable of acquiring long-term, continuous time-series data from current-generation small or large, dynamic wind-turbine rotors. Meetings with wind-turbine research personnel at NREL and SNL resulted in a list of the major requirements that the system must meet. Initial attempts to locate a commercial system that could meet all of these requirements were not successful, but some commercially available data acquisition and radio/modem subsystems that met many of the requirements were identified. A time synchronization subsystem and a programmable logic device subsystem to integrate the functions of the data acquisition, the radio/modem, and the time synchronization subsystems and to communicate with the user have been developed at SNL. This paper presents the data system requirements, describes the four major subsystems comprising the system, summarizes the current status of the system, and presents the current plans for near-term development of hardware and software.
Disordered polymethacrylonitrile (PMAN) carbon monoliths have been studied as potential tailored electrodes for lithium ion batteries. A combination of electrochemical and surface spectroscopic probes have been used to investigate irreversible loss mechanisms. Voltammetric measurements show that Li intercalates readily into the carbon at potentials 1V positive of the reversible Li potential. The coulometric efficiency rises rapidly from 50% for the first potential cycle to greater than 85% for the third cycle, indicating that solvent decomposition is a self-limiting process. Surface film composition and thickness, as measured by x-ray photoelectron spectroscopy (XPS) and secondary ion mass spectrometry (SIMS), does not vary substantially when compared to more ordered carbon surfaces. Li{sup +} profiles are particularly useful in discriminating between the bound states of Li at the surface of solution permeable PMAN carbons.
VICTORIA is a mechanistic computer code designed to analyze fission product behavior within a nuclear reactor coolant system (RCS) during a severe accident. It provides detailed predictions of the release of radioactive and nonradioactive materials from the reactor core and transport and deposition of these materials within the RCS. A summary of the results and recommendations of an independent peer review of VICTORIA by the US Nuclear Regulatory Commission (NRC) is presented, along with recent applications of the code. The latter include analyses of a temperature-induced steam generator tube rupture sequence and post-test analyses of the Phebus FPT-1 test. The next planned Phebus test, FTP-4, will focus on fission product releases from a rubble bed, especially those of the less-volatile elements, and on the speciation of the released elements. Pretest analyses using VICTORIA to estimate the magnitude and timing of releases are presented. The predicted release of uranium is a matter of particular importance because of concern about filter plugging during the test.
The US Department of Energy plans to dispose of transuranic waste at the Waste Isolation Pilot Plant (WIPP), which is sited in southeastern New Mexico. The WIPP disposal facility is located approximately 2,150 feet (650 m) below surface in the bedded halite of the Salado Formation. Prior to initiation of disposal activities, the Department of Energy must demonstrate that the WIPP will comply with all regulatory requirements. Applicable regulations require that contaminant releases from the WIPP remain below specified levels for a period of 10,000 years. To demonstrate that the WIPP will comply with these regulations, the Department of Energy has requested that Sandia National Laboratories develop and implement a comprehensive performance assessment of the WIPP repository for the regulatory period. This document presents the conceptual model of the shaft sealing system to be implemented in performance assessment calculations conducted in support of the Compliance Certification Application for the WIPP. The model was developed for use in repository-scale calculations and includes the seal system geometry and materials to be used in grid development as well as all parameters needed to describe the seal materials. These calculations predict the hydrologic behavior of the system. Hence conceptual model development is limited to those processes that could impact the fluid flow through the seal system.
This contribution extends the Outside Nodal Hierarchy List (ONHL) procedures described in ATM Form Contribution 97-0766. These extensions allow multiple mobile networks to form either an ad hoc network or an extension of a fixed PNNI infrastructure. This contribution covers the simplest case where the top-most Logical Group Nodes (LGNs), in those mobile networks, all reside at the same level in a PNNI hierarchy. Future contributions will cover the general case where those top-most LGNs reside at different hierarchy levels. This contribution considers a flat ad hoc network architecture--in the sense that each mobile network always participates in the PNNI hierarchy at the preconfigured level of its top-most LGN.
Recent advances in smart materials have renewed interest in the development of improved manufacturing processes featuring sensing, processing, and active control. In particular, vibration suppression in metal cutting has received much attention because of its potential for enhancing part quality while reducing the time and cost of production. Although active tool clamps have been recently demonstrated, they are often accompanied by interfacing issues that limit their applicability to specific machines. Under the auspices of the Laboratory Directed Research and Development program, the project titled {open_quotes}Smart Cutting Tools for Precision Manufacturing{close_quotes} developed an alternative approach to active vibration control in machining. Using the boring process as a vehicle for exploration, a commercially available tool was modified to incorporate PZT stack actuators for active suppression of its bending modes. Since the modified tool requires no specialized mounting hardware, it can be readily mounted on many machines. Cutting tests conducted on a horizontal lathe fitted with a hardened steel workpiece verify that the actively damped boring bar yields significant vibration reduction and improved surface finishes as compared to an unmodified tool.
Throughout Sandia`s history, products have been represented by drawings. Solid modeling systems have recently replaced drawings as the preferred means for representing product geometry. These systems are used for product visualization, engineering analysis and manufacturing planning. Unfortunately, solid modeling technology is inadequate for life cycle systems engineering, which requires maintenance of technical history, efficient management of geometric and non-geometric data, and explicit representation of engineering and manufacturing characteristics. Such information is not part of the mathematical foundation of solid modeling. The current state-of-the-art in life cycle engineering is comprised of painstakingly created special purpose tools, which often are incompatible. New research on {open_quotes}chain modeling{close_quotes} provides a method of chaining the functionality of a part to the geometric representation. Chain modeling extends classical solid modeling to include physical, manufacturing, and procedural information required for life cycle engineering. In addition, chain modeling promises to provide the missing theoretical basis for Sandia`s parent/child product realization paradigm. In chain modeling, artifacts and systems are characterized in terms of their combinatorial properties: cell complexes, chains, and their operators. This approach is firmly rooted in algebraic topology and is a natural extension of current technology. The potential benefits of this approach include explicit hierarchical and combinatorial representation of physics, geometry, functionality, test, and legacy data in a common computational framework that supports a rational decision process and partial design automation. Chain modeling will have a significant impact on design preservation, system identification, parameterization, system reliability, and design simplification.
The Laser Sensor No. 1 (LS1) is a system designed and built by Sandia to detect and report laser illumination of an orbiting satellite. It was launched March 1994 as part of the U.S. Air Force Phillips Laboratory, Technology for Autonomous Operational Survivability (TAOS) satellite program. The engineering details of the system are described in this report. Operation characteristics and results have been reserved for inclusion in a classified Air Force report prepared by the TAOS Program Office of Phillips Laboratory.
Manufacturers widely recognize testing as a major factor in the cost, producability, and delivery of product in the $100 billion integrated circuit business: {open_quotes}The rapid development of VLSI using sub-micron CMOS technology has suddenly exposed traditional test techniques as a major cost factor that could restrict the development of VLSI devices exceeding 512 pins an operating frequencies above 200 MHz.{close_quotes} -- 1994 Semiconductor Industry Association Roadmap, Design and Test, Summary, pg. 43. This problem increases dramatically for stockpile electronics, where small production quantities make it difficult to amortize the cost of increasingly expensive testers. Application of multiple ICs in Multi-Chip Modules (MCM) greatly multiplies testing problems for commercial and defense users alike. By traditional test methods, each new design requires custom test hardware and software and often dedicated testing equipment costing millions of dollars. Also, physical properties of traditional test systems often dedicated testing equipment costing millions of dollars. Also, physical properties of traditional test systems limit capabilities in testing at-speed (>200 MHz), high-impedance, and high-accuracy analog signals. This project proposed a revolutionary approach to these problems: replace the multi-million dollar external test system with an inexpensive test system integrated onto the product wafer. Such a methodology enables testing functions otherwise unachievable by conventional means, particularly in the areas of high-frequency, at-speed testing, high impedance analog circuits, and known good die assessment. The techniques apply specifically to low volume applications, typical of Defense Programs, where testing costs represent an unusually high proportional of product costs, not easily amortized.
This document describes the DOSFAC2 code, which is used for generating dose-to-source conversion factors for the MACCS2 code. DOSFAC2 is a revised and updated version of the DOSFAC code that was distributed with version 1.5.11 of the MACCS code. included are (1) an overview and background of DOSFAC2, (2) a summary of two new functional capabilities, and (3) a user`s guide. 20 refs., 5 tabs.
Computer modeling of Chemical Vapor Deposition (CVD) reactors can greatly aid in the understanding, design, and optimization of these complex systems. Modeling is particularly attractive in these systems since the costs of experimentally evaluating many design alternatives can be prohibitively expensive, time consuming, and even dangerous, when working with toxic chemicals like Arsine (AsH{sub 3}): until now, predictive modeling has not been possible for most systems since the behavior is three-dimensional and governed by complex reaction mechanisms. In addition, CVD reactors often exhibit large thermal gradients, large changes in physical properties over regions of the domain, and significant thermal diffusion for gas mixtures with widely varying molecular weights. As a result, significant simplifications in the models have been made which erode the accuracy of the models` predictions. In this paper, the authors will demonstrate how the vast computational resources of massively parallel computers can be exploited to make possible the analysis of models that include coupled fluid flow and detailed chemistry in three-dimensional domains. For the most part, models have either simplified the reaction mechanisms and concentrated on the fluid flow, or have simplified the fluid flow and concentrated on rigorous reactions. An important CVD research thrust has been in detailed modeling of fluid flow and heat transfer in the reactor vessel, treating transport and reaction of chemical species either very simply or as a totally decoupled problem. Using the analogy between heat transfer and mass transfer, and the fact that deposition is often diffusion limited, much can be learned from these calculations; however, the effects of thermal diffusion, the change in physical properties with composition, and the incorporation of surface reaction mechanisms are not included in this model, nor can transitions to three-dimensional flows be detected.
This paper documents an investigation of approaches to improving the quality of Pro/Engineer-created solid model data for use by downstream applications. The investigation identified a number of sources of problems caused by deficiencies in Pro/Engineer`s geometric engine, and developed prototype software capable of detecting many of these problems and guiding users towards simplified, useable models. The prototype software was tested using Sandia production solid models, and provided significant leverage in attacking the simplification problem.
The CONTAIN 2.0 computer code is an integrated analysis tool used for predicting the physical conditions, chemical compositions, and distributions of radiological materials inside a containment building following the release of material from the primary system in a light-water reactor accident. It can also predict the source term to the environment. CONTAIN 2.0 is intended to replace the earlier CONTAIN 1.12, which was released in 1991. The purpose of this Code Manual is to provide full documentation of the features and models in CONTAIN 2.0. Besides complete descriptions of the models, this Code Manual provides a complete description of the input and output from the code. CONTAIN 2.0 is a highly flexible and modular code that can run problems that are either quite simple or highly complex. An important aspect of CONTAIN is that the interactions among thermal-hydraulic phenomena, aerosol behavior, and fission product behavior are taken into account. The code includes atmospheric models for steam/air thermodynamics, intercell flows, condensation/evaporation on structures and aerosols, aerosol behavior, and gas combustion. It also includes models for reactor cavity phenomena such as core-concrete interactions and coolant pool boiling. Heat conduction in structures, fission product decay and transport, radioactive decay heating, and the thermal-hydraulic and fission product decontamination effects of engineered safety features are also modeled. To the extent possible, the best available models for severe accident phenomena have been incorporated into CONTAIN, but it is intrinsic to the nature of accident analysis that significant uncertainty exists regarding numerous phenomena. In those cases, sensitivity studies can be performed with CONTAIN by means of user-specified input parameters. Thus, the code can be viewed as a tool designed to assist the knowledge reactor safety analyst in evaluating the consequences of specific modeling assumptions.
This report provides a summary of the Pulser In a Chip 9000-Discretionary LDRD. The program began in January of 1997 and concluded in September of 1997. The over-arching goal of this LDRD is to study whether laser diode triggered photoconductive semiconductor switches (PCSS) can be used to activate electro-optic devices such as Q-switches and Pockels cells and to study possible laser diode/switch integration. The PCSS switches we used were high gain GaAs switches because they can be triggered with small amounts of laser light. The specific goals of the LDRD were to demonstrate: (1) that small laser diode arrays that are potential candidates for laser-switch integration will indeed trigger the PCSS switch, and (2) that high gain GaAs switches can be used to trigger optical Q-switches in lasers such as the lasers to be used in the X-1 Advanced Radiation Source and the laser used for direct optical initiation (DOI) of explosives. The technology developed with this LDRD is now the prime candidate for triggering the Q switch in the multiple lasers in the laser trigger system of the X-1 Advanced Radiation Source and may be utilized in other accelerators. As part of the LDRD we developed a commercial supplier. To study laser/switch integration we tested triggering the high gain GaAs switches with: edge emitting laser diodes, vertical cavity surface emitting lasers (VCSELs), and transverse junction stripe (TJS) lasers. The first two types of lasers (edge emitting and VCSELs) did activate the PCSS but are harder to integrate with the PCSS for a compact package. The US lasers, while easier to integrate with the switch, did not trigger the PCSS at the US laser power levels we used. The PCSS was used to activate the Q-switch of the compact laser to be used in the X-1 Advanced Radiation Source.
During November/96 to April/97 Sandia National Laboratories provided consulation, data collection, analysis and project documentation to the U.S. Army for a series of four geothermal exploratory slimholes drilled on the McGregor Range approximately 25 miles north of El Paso, Texas. This drilling was directed toward evaluating a potential reservoir for geothermal power generation in this area, with a secondary objective of assessing the potential for direct use applications such as space heating or water de-salinization. This report includes: representative temperature logs from the wells; daily drilling reports; a narrative account of the drilling and testing; a description of equipment used; a summary and preliminary interpretation of the data; and recommendations for future work.
The WCEDS prototype software system was developed to investigate the usefulness of waveform correlation methods for CTBT monitoring. The WCEDS prototype performs global seismic event detection and has been used in numerous experiments. This report documents the software system design, presenting an overview of the system operation, describing the system functions, tracing the information flow through the system, discussing the software structures, and describing the subsystem services and interactions. The effectiveness of the software design in meeting project objectives is considered, as well as opportunities for code refuse and lessons learned from the development process. The report concludes with recommendations for modifications and additions envisioned for regional waveform-correlation-based detector.
This report presents a detailed analysis of the results from fatigue studies of wind turbine blade composite materials carried out at Montana State University (MSU) over the last seven years. It is intended to be used in conjunction with the DOE/MSU composite Materials Fatigue Database. The fatigue testing of composite materials requires the adaptation of standard test methods to the particular composite structure of concern. The stranded fabric E-glass reinforcement used by many blade manufacturers has required the development of several test modifications to obtain valid test data for materials with particular reinforcement details, over the required range of tensile and compressive loadings. Additionally, a novel testing approach to high frequency (100 Hz) testing for high cycle fatigue using minicoupons has been developed and validated. The database for standard coupon tests now includes over 4,100 data points for over 110 materials systems. The report analyzes the database for trends and transitions in static and fatigue behavior with various materials parameters. Parameters explored are reinforcement fabric architecture, fiber content, content of fibers oriented in the load direction, matrix material, and loading parameters (tension, compression, and reversed loading). Significant transitions from good fatigue resistance to poor fatigue resistance are evident in the range of materials currently used in many blades. A preliminary evaluation of knockdowns for selected structural details is also presented. The high frequency database provides a significant set of data for various loading conditions in the longitudinal and transverse directions of unidirectional composites out to 10{sup 8} cycles. The results are expressed in stress and strain based Goodman Diagrams suitable for design. A discussion is provided to guide the user of the database in its application to blade design.
