Publications

There is a growing need for multi-axis force torque (F/T) sensors to aid in the assembly of micro-scale devices. Many current generation robotic microassembly systems lack the force-feedback needed to facilitate automating common assembly tasks, such as peg-in-hole insertions. Currently, most microassembly operations use vision systems to align components being assembled. However, it is difficult to view high aspect ratio component assemblies under high magnification due to the resulting limited depth-of-field. In addition, this difficulty is compounded as assembly tolerances approach dimensions resolvable with optics or if the mating parts are delicate. This paper describes the development of a high sensitivity F/T sensor. Optimal design theory was applied to determine the configuration that would result in the most sensitive and accurate sensor: Calibration experiments demonstrated that the sensor can resolve down to 200μN and possibly less. Copyright © 2005 by ASME.

Sandia National Laboratories is exploring assembling micro, meso, and miniature scale parts into a variety of tiny devices. These devices are comprised of parts ranging from tens of microns to a few millimeters in size. In support of this activity, a rapid prototyping assembly workstation that enables an operator to assemble three-dimensional devices with a minimum of fixturing has been developed. This workstation consists of precision robotics, stages, cameras, and sensors integrated in a way that facilitates human interaction. Although many of the workstation components are commercially available, no inexpensive and durable grippers of suitably large range of motion could be found. This paper describes the design and testing of a novel micro gripper based on precision tweezers and actuated with a micro servo that has proven extremely useful for the operator directed assembly of micro scale devices. Copyright © 2005 by ASME.

Micro-scale welding has been successfully demonstrated using a Scanning Electron Microscope-based Electron Beam Welding (μEBW) technique. Modifications to a standard SEM to increase beam power, beam diagnostics, and Monte Carlo simulations of energy deposition are used to discuss how the technique may be used in practice. In particular, beam-material sub-surface interaction volumes and energy source location tailoring effects will be discussed. Additional desirable enhancements for the future will be noted. Copyright © 2006 ASM International®.

In this paper, we discuss the primary characteristics and pitfalls associated with the use of Bragg Gratings for distributed temperature sensing, with particular attention to time-division multiplexing (TDM). Two pitfalls are intrinsic to a serial array of such gratings that use TDM: spectral shadowing and crosstalk. Two others involve strain in the fiber that masquerades as temperature and that could affect other methods of interrogating the gratings, in addition to TDM.

During VAR of a 5377 kg, 0.76 m diameter Ti-6Al-4V alloy electrode into 0.86 m diameter ingot, tantalum balls were dropped into the ingot pool to measure the centerline pool depth. The first was introduced at full power after 1134 kg of electrode had been melted. A second marker was dropped after 4288 kg of electrode had been consumed, also at full power but just prior to power cutback. The third, and final, ball was released at the end of the cutback with 286 kg of electrode remaining. An external solenoidal stirring field was applied to the ingot throughout the melting process, as is typical in such practices. The ingot was sectioned, the marker ball positions recorded, and the pool depths subsequently calculated. The first market was located only 4.5 cm from the bottom of the ingot, but was off-center by nearly 22 cm, indicating a relatively flat pool bottom. The other two balls were located 36.2 cm and 105.4 cm from the bottom, both approximately centered. Pool depths for the three conditions were calculated to be ∼41 cm, ∼131 cm and ∼99 cm. BAR, a 21/2 D, axisymmetric ingot code developed at Sandia National Laboratories, was used to generate pool shapes corresponding to these conditions. The code, which solves heat transfer, fluid flow and electromagnetic effects in a coupled fashion, was able to match the pool depths by adjusting the strength of the stirring field as a parameter, and predicted relatively thin sidewalls under full power melting, a prediction supported by crucible temperature and current distribution data also collected during the test. The applied stirring field was 60 gauss for this test. The effective field strength setting in BAR required to match the pool depths was 30 gauss. All other parameters in BAR were set identical to those required to match low stirring field (4 gauss), full power ingot pool depths measured and reported in an earlier study, except those requiring consistency with observed arc behavior in the two cases. Thus, it is concluded that the 21/2 D code can accurately match pool depths under high field strength stirring conditions once properly benchmarked.

Simulation results demonstrating transmission enhancement through a sub-wavelength aperature in an infinite plasmon array are presented. The results are obtained using EIGER and are considered preliminary before proceeding to the simulation of finite-plasmon arrays.

This paper compares several linear-theory-based models for droplet shattering employed for simulations of spray impingement on flat wall surface or a circular cylinder. Numerical simulations are conducted using a stochastic separated flow (SSF) technique that includes sub-models for droplet dynamics and impact. Results for spray impingement over a flat wall indicate that the linear theory applicable for a single droplet impact over-predicts the number of satellite (or secondary) droplets upon shattering when compared to experimental data. The causes for the observed discrepancies are discussed. Numerical simulation results for spray impingement over for a circular cylinder in cross flow are obtained and discussed. © 2005 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.

Grain boundary stiffness and mobility determine the kinetics of curvature driven grain growth. Here the stiffness and mobility are determined using a computational approach based on the analysis of fluctuations in the grain boundary position during molecular dynamics simulations. This work represents the first determination of grain boundary stiffness. The results indicate that the boundary stiffness for a given boundary plane has a strong dependence on the direction of the boundary distortion. The mobility deduced is in accord with previous computer simulation studies.

We present a proportional hazards model (PHM) that establishes a framework suitable for performing reliability estimates and risk prognostics on complex multi-component systems which are transferred at arbitrary times among a discrete set of non-stationary stochastic environments. Such a scenario is not at all uncommon for portable and mobile systems. It is assumed that survival data, possibly interval censored, is available at several "typical" environments. This collection of empirical survival data forms the foundation upon which the basic effects of selected covariates are incorporated via the proportional hazards model. Proportional hazards models are well known in medical statistics, and can provide a variety of data-driven risk models which effectively capture the effects of the covariates. The paper describes three modifications we have found most suitable for this class of systems: development of suitable survival estimators that function well under realistic censoring scenarios, our modifications to the PHM which accommodate time-varying stochastic covariates, and implementation of said model in a non-linear network context which is itself model-free. Our baseline hazard is a parameterized reliability model developed from the empirical reliability estimates. Development of the risk score for arbitrary covariates arising from movement among different random environments is through interaction of the non-linear network and training data obtained from a Markov chain simulation based on stochastic environmental responses generated from Karhunen-Loève models. Copyright © 2005 by ASME.

The effect of proton energy on single-event latchup (SEL) in present-day SRAMs is investigated over a wide range of proton energies and temperature. SRAMs from five different vendors were irradiated at proton energies from 20 to 500 MeV and at temperatures of 25° and 85°C. For the SRAMs and radiation conditions examined in this work, proton energy SEL thresholds varied from as low as 20 MeV to as high as 490 MeV. To gain insight into the observed effects, the heavy-ion SEL linear energy transfer (LET) thresholds of the SRAMs were measured and compared to high-energy transport calculations of proton interactions with different materials. For some SRAMs that showed proton-induced SEL, the heavy-ion SEL threshold LET was as high as 25 MeV-cm 2/mg. Proton interactions with Si cannot generate nuclear recoils with LETs this large. Our nuclear scattering calculations suggest that the nuclear recoils are generated by proton interactions with tungsten. Tungsten plugs are commonly used in most high-density ICs fabricated today, including SRAMs. These results demonstrate that for system applications where latchups cannot be tolerated, SEL hardness assurance testing should be performed at a proton energy at least as high as the highest proton energy present in the system environment. Moreover, the best procedure to ensure that ICs will be latchup free in proton environments may be to use a heavy-ion source with LETs ≥40 MeV-cm 2/mg. © 2005 IEEE.

Oxygen-enhanced and oxygen-fired pulverized coal combustion is actively being investigated, to achieve emission reductions and reduction in flue gas cleanup costs, as well as for coal-bed methane and enhanced oil recovery applications. To fully understand the results of pilot-scale tests and to accurately predict scale-up performance through CFD modeling, fundamental data are needed concerning coal char combustion under these conditions. In the work reported here, the effect of enhanced oxygen levels and CO2 bath gas are independently analyzed for their influence on a single-particle pulverized coal ignition of a U.S. bituminous coal and its char. The experiments show that the presence of CO2 and a lower O2 concentration increase the ignition delay time of both coal and char particles. The char particle results are explained by the difference in the mass diffusivity of CO 2 and N2, whereas the coal particle results require further analysis. © (2005) by the International Pittsburgh Coal Conference.

A physical parameter based model for dielectric charge accumulation is proposed and used to predict the displacement versus applied voltage and pull-in response of an electrostatic MEMS wavelength selective integrated optical switch. ©2005 IEEE.

Abstract not provided.

CMMs equipped with non-contact probes, such as video probes, are becoming popular for a variety of 2-D or 2.5-D objects. The advantages of a video (or vision) probe include the ability to measure features which are either too small or too delicate for a touch probe. Unfortunately, vision-based probing systems do not have the same measurement accuracy as touch probe equipped machines. For example, a Moore M48 coordinate measurement machine has an expected measurement uncertainty of 0.2 μm (plus a scale dependent term) when using a touch probe (the actual repeatability is on the order of 0.03 μm). When the probe is changed to a Leitz LS1 vision system, the expected measurement uncertainty is 1.2 μm plus a scale dependent term. The decreased accuracy is due entirely to the change in probing method. Components of the error budget include environmental effects, choice of lighting, lens distortions, and stage 2-D accuracy. Lighting is a major contributor to the measurement error budget, especially when a bidirectional measurement needs to be made (for example, the width of a line, rather than the center location of a line). We report on the effect of the sensitivity of vision probing on an OGP Avant Apex 200 to different lighting conditions, both for unidirectional and bidirectional measurements.

One of the challenges facing microrobotic manufacturing is the ability to sense interactions for force-guided assembly of small devices. There is a need for a force transducer with the ability to sense forces in multiple degrees-of-freedom in the mN range with resolution on the order of 10 μN for microassembly applications. This paper presents theoretical studies for developing a surface micromachined piezoresistive force transducer that can measure normal force in the z-direction and moments about the x and y-axes. The devices proposed here are based on a compliant platform design with integrated piezoresistive sensing elements fabricated in a modified SUMMiT process. Various configurations and sensor element layouts are explored to determine the relationship of the applied forces and moments experienced during assembly and the corresponding strain. Structural and finite element analysis is used to determine the elastic response of the device and establish the best locations and orientations of the sensing elements to effectively utilize the piezoresistive effect of the polysilicon sensors. Initial experiments show the polysilicon piezoresistors to have a gauge factor of approximately 25. The expected sensitivities for these devices are presented. Copyright © 2005 by ASME.

Sandia National Laboratories has developed a mesoscale wheeled hopping vehicle (WHV) to overcome the longstanding problems of mobility and power in small scale unmanned vehicles. The system provides mobility in situations such as negotiating obstacles in the vertical dimension and rough terrain that are prohibitive for other small ground base vehicles.

The human brain functions through a chemically-induced biological process which operates in a manner similar to electrical systems. The signal resulting from this biochemical process can actually be monitored and read using tools and having patterns similar to those found in electrical and electronics engineering. The primary signature of this electrical activity is the ''brain wave'', which looks remarkably similar to the output of many electrical systems. Likewise, the device currently used in medical arenas to read brain electrical activity is the electroencephalogram (EEG) which is synonymous with a multi-channel oscilloscope reading. Brain wave readings and recordings for medical purposes are traditionally taken in clinical settings such as hospitals, laboratories or diagnostic clinics. The signal is captured via externally applied scalp electrodes using semi-viscous gel to reduce impedance. The signal will be in the 10 to 100 microvolt range. In other instances, where surgeons are attempting to isolate particular types of minute brain signals, the electrodes may actually be temporarily implanted in the brain during a preliminary procedure. The current configurations of equipment required for EEGs involve large recording instruments, many electrodes, wires, and large amounts of hard disk space devoted to storing large files of brain wave data which are then eventually analyzed for patterns of concern. Advances in sensors, signal processing, data storage and microelectronics over the last decade would seem to have paved the way for the realization of devices capable of ''real time'' external monitoring, and possible assessment, of brain activity. A myriad of applications for such a capability are likewise presenting themselves, including the ability to assess brain functioning, level of functioning and malfunctioning. Our plan is to develop the sensors, signal processing, and portable instrumentation package which could capture, analyze, and communicate information on brain activity which could be of use to the individual, medical personnel or in other potential arenas. To take this option one step further, one might foresee that the signal would be captured, analyzed, and communicated to a person or device and which would result an action or reaction by that person or device. It is envisioned that ultimately a system would include a sensor detection mechanism, transmitter, receiver, microprocessor and associated memory, and audio and/or visual alert system. If successful in prototyping, the device could be considered for eventual implementation in ASIC form or as a fully integrated CMOS microsystem.

The production of Ultra-cold molecules is a goal of many laboratories through out the world. Here we are pursuing a unique technique that utilizes the kinematics of atomic and molecular collisions to achieve the goal of producing substantial numbers of sub Kelvin molecules confined in a trap. Here a trap is defined as an apparatus that spatially localizes, in a known location in the laboratory, a sample of molecules whose temperature is below one degree absolute Kelvin. Further, the storage time for the molecules must be sufficient to measure and possibly further cool the molecules. We utilize a technique unique to Sandia to form cold molecules from near mass degenerate collisions between atoms and molecules. This report describes the progress we have made using this novel technique and the further progress towards trapping molecules we have cooled.

The purpose of this project was to do some preliminary studies and process development on electroactive polymers to be used for tunable optical elements and MEMS actuators. Working in collaboration between Sandia National Labs and The University of Illinois Urbana-Champaign, we have successfully developed a process for applying thin films of poly (vinylidene fluoride) (PVDF) onto glass substrates and patterning these using a novel stamping technique. We observed actuation in these structures in static and dynamic measurements. Further work is needed to characterize the impact that this approach could have on the field of tunable optical devices for sensing and communication.

This Pollution Prevention Opportunity Assessment (PPOA) was conducted for the two Sandia National Laboratories/New Mexico cafeteria facilities between May and August 2005. The primary purpose of this PPOA is to assess waste and resource reduction opportunities and issue Pollution Prevention (P2) recommendations for Sandia's food service facilities. This PPOA contains recommendations for energy, water and resource reduction, as well as material substitution based upon environmentally preferable purchasing. Division 3000 has requested the PPOA report as part of the Division's compliance effort to implement the Environmental Management System (EMS) per DOE Order 450.1. This report contains a summary of the information collected and analyses performed with recommended options for implementation. The SNL/NM P2 Group will work with Division 3000 and the respective cafeteria facilities to implement these options.

Sandia National Laboratories (SNL) has limited inventories of, and activities with, fissile-material. Personnel who perform nuclear criticality safety (NCS) assignments do so on a part-time basis. Sandia's "tailored approach" to training and qualification of these personnel can serve as a model for others with "small" NCS programs. SNL uses a single set of qualification cards for qualifying nuclear criticality safety engineers (NCSE). Provision is made for: (1) training and mentoring of new NCSE with testing or other verification of their skills and knowledge and (2) "qualification by documentation" for staff who historically have been performing NCSE-like duties. Key areas for evaluation include previous formal education and training; demonstrated success in writing Criticality Safety Assessments (CSA) and related documents; interaction with the SNL criticality safety committees; and overall knowledge (e.g., as judged against the objectives in DOE-STD-1135). Gaps of knowledge are filled through self-study, training, or mentoring. Candidate mastery of topics is confirmed primarily by evaluation of work products and interviews. Completion is approved by the Criticality Safety Officer (CSO) - the closest SNL comes to having an NCS manager - and then management. In applying the tailored approach, NCSE candidates are not required to be subject-matter experts for all NCS-related facilities and activities at SNL at the time of qualification. Familiarity with each of the facilities and activities is expected, along with the ability to "self-train" when needed (e.g., analogous just-in-time [JIT] procurement). The latter is supported by identification of applicable SNL-wide fissile-material facilities and activities along with resource organizations and personnel in NCS, safety analysis, accountability, etc. The capstone is a discussion with the CSO, or other experienced NCSE, demonstrating the ability to explain in some detail how a specific NCS assignment would be tackled (e.g., options for gaining facility/activity knowledge, performing analyses, using resource personnel, and traversing the required peer- and committee-review processes).

Red Storm is an Advanced Simulation and Computing (ASC) funded massively parallel supercomputer located at Sandia National Laboratories (SNL). The Red Storm Usage Model (RSUM) documents the capabilities and the environment provided for the FY05 Tri-Lab Level II Limited Availability Red Storm User Environment Milestone and the FY05 SNL Level II Limited Availability Red Storm Platform Milestone. This document describes specific capabilities, tools, and procedures to support both local and remote users. The model is focused on the needs of the ASC user working in the secure computing environments at Los Alamos National Laboratory (LANL), Lawrence Livermore National Laboratory (LLNL), and SNL. Additionally, the Red Storm Usage Model maps the provided capabilities to the Tri-Lab ASC Computing Environment (ACE) requirements. The ACE requirements reflect the high performance computing requirements for the ASC community and have been updated in FY05 to reflect the community's needs. For each section of the RSUM, Appendix I maps the ACE requirements to the Limited Availability User Environment capabilities and includes a description of ACE requirements met and those requirements that are not met in that particular section. The Red Storm Usage Model, along with the ACE mappings, has been issued and vetted throughout the Tri-Lab community.

Focused Beams from high-power lasers have been used to command trigger gas switches in pulse power accelerators for more than two decades. This Laboratory-Directed Research and Development project was aimed at determining whether high power lasers could also command trigger water switches on high-power accelerators. In initial work, we determined that focused light from three harmonics of a small pulsed Nd:YAG laser at 1064 nm, 532 nm, and 355 nm could be used to form breakdown arcs in water, with the lowest breakdown thresholds of 110 J/cm{sup 2} or 14 GW/cm{sup 2} at 532 nm in the green. In laboratory-scale laser triggering experiments with a 170-kV pulse-charged water switch with a 3-mm anode-cathode gap, we demonstrated that {approx}90 mJ of green laser energy could trigger the gap with a 1-{sigma} jitter of less than 2ns, a factor of 10 improvement over the jitter of the switch in its self breaking mode. In the laboratory-scale experiments we developed optical techniques utilizing polarization rotation of a probe laser beam to measure current in switch channels and electric field enhancements near streamer heads. In the final year of the project, we constructed a pulse-power facility to allow us to test laser triggering of water switches from 0.6- MV to 2.0 MV. Triggering experiments on this facility using an axicon lens for focusing the laser and a switch with a 740 kV self-break voltage produced consistent laser triggering with a {+-} 16-ns 1-{sigma} jitter, a significant improvement over the {+-} 24-ns jitter in the self-breaking mode.

Over the past few years we have developed the ability to acquire images through a confocal microscope that contain, for each pixel, the simultaneous fluorescence lifetime and spectra of multiple fluorophores within that pixel. We have demonstrated that our system has the sensitivity to make these measurements on single molecules. The spectra and lifetimes of fluorophores bound to complex molecules contain a wealth of information on the conformational dynamics and local chemical environments of the molecules. However, the detailed record of spectral and temporal information our system provides from fluorophores in single molecules has not been previously available. Therefore, we have studied several fluorophores and simple fluorophore-molecule systems that are representative of the use of fluorophores in biological systems. Experiments include studies of a simple fluorescence resonance energy transfer (FRET) system, green fluorescent probe variants and quantum dots. This work is intended to provide a basis for understanding how fluorophores report on the chemistry of more complex biological molecules.

Abstract not provided.