Publications

Voltage and temperature distributions along the crucible were measured during VAR of 0.81 m diameter Ti-6Al-4V electrode into 0.91 m diameter ingot. These data were used to determine the current distribution along the crucible. Measurements were made for two furnace conditions, one with a bare crucible and the other with a painted crucible. The VAR furnace used for these measurements is of the non-coaxial type, i.e. current is fed directly into the bottom of the crucible through a stool (base plate) contact and exits the furnace through the electrode stinger. The data show that approximately 63% of the current is conducted directly between the ingot and electrode with the remaining conducted between the electrode and crucible wall. This partitioning does not appear to be sensitive to crucible coating. The crucible voltage data were successfully simulated using uniform current distributions for the current conduction zones, a value of 0.63 for the partitioning, and widths of 0.30 and 0.15 m for the ingot/crucible wall and plasma conduction zones, respectively. Successful simulation of the voltage data becomes increasingly difficult (or impossible) as one uses current partitioning values increasingly different from 0.63, indicating that the experimental value is consistent with theory. Current conducted between the ingot and crucible wall through the ingot/wall contact zone may vary during the process without affecting overall current partitioning. The same is true for current conducted through the ingot/stool and stool/crucible contact zones. There is some evidence that the ingot/stool current decreases with increasing ingot length for the case of the bare crucible. Equivalent circuit analysis shows that, under normal conditions, current partitioning is only sensitive to the ratio of the plasma resistance across the annulus to the plasma resistance across the electrode gap, thereby demonstrating the relationship between current partitioning and gap.

A comparison is made between numerical simulations and experimental data for soot and water vapor concentration in a JP-8 fire. Soot concentration depends on soot generated/destroyed per unit flame area (subgrid soot model) and the overall flame area per unit volume (turbulence treatment). Two different turbulence treatments, a steady RANS variant and an unsteady LES variant, are used to determine the effect of overall flame area per unit volume. The results indicate that the difference in the two turbulence treatments is greater than the difference between the data and either approach. Copyright © 2005 by ASME.

The ability of current modeling and simulation tools to accurately predict a building fire of practical size and duration is at issue. Modeling is challenged by computational cost, fidelity of assumed physics, and correct knowledge of initial and boundary conditions. A series of simulations has been conducted to compare with experiments for a fuel fire in a facility. The purpose of the study was to understand the importance of simulation parameters. The test geometry is sufficiently large and the fire of long enough duration to present a challenge to model in detail. Several computational parameters have been varied at magnitudes consistent with the uncertainty in the parameter to determine the parametric sensitivities. The predicted heat flux inside the facility was sensitive to varying degrees to the parameters selected for the study, with those related to the fuel source being the most important physical parameters. Copyright © 2005 by ASME.

Studies were conducted to determine what relationships may exist between alloy compositions and inertia friction weld microstructures of austenitic stainless steels. Ternary alloys of iron, nickel and chromium with 60-70% Fe and a range in Cr/Ni ratios from 0.34 to 1.9 were investigated. It was found that although grain size and compositional banding were reduced and varied with radial position and weld parameters, no significant solid-state transformation between ferrite and austenite was detected. Ferrite stringers in base materials with high ferrite content were elongated and fragmented, while in base materials with small amounts of ferrite stringers the ferrite dissolved. These findings may vary for different sample geometries and weld schedules. Copyright © 2006 ASM International®.

Tubular specimens of the nitrogen-strengthened alloy 21Cr-6Ni-9Mn were instrumented with thermocouples and inertia welded using a wide range of axial forces and kinetic energies. It was determined that a linear relationship exists between upset and kinetic energy for a given axial force. Furthermore, the peak temperatures are inversely related to the applied axial force. Microstructural characterization was performed using optical and electron microscopy techniques. Ferrite was observed locally at the weld interface, and it was determined that the width of the ferrite zone could vary widely depending on the process parameters. Electron backscattered diffraction analysis revealed that the ferrite and austenite at the weld interface exhibit the Kurdjumov-Sachs orientation relationship, and suggests that a very large amount of ferrite is present during the welding process that subsequently transforms to austenite during cooling. The fracture toughness of inertia welds thermally charged in gaseous hydrogen was also measured. It was found that the hydrogen-assisted fracture susceptibility of the inertia welds was greater than that of the base metal, but less than that of 21Cr-6Ni-9Mn gas tungsten arc welds. Copyright © 2006 ASM International®.

High speed, high resolution video observations of solidification cracking in longitudinal Varestraint tests of Alloy 718 reveal a number of important features of the test. For large augmented strains, crack initiation occurs at a liquid fraction of approximately 0.2, and crack growth proceeds in both advancing (growth in the torch travel direction) and retreating (growth away from the trailing edge) directions. For the advancing crack, the average growth velocity is identical to the travel speed, indicating that the advancing tip grows at isothermal temperature and consequently, a fixed liquid fraction. Termination of the advancing crack tip occurs as the augmented strain field diminishes. The retreating crack tip grows in an increasing strain field and decreasing temperature, and appears to terminate when the crack tip intersects the solidus. These observations define criteria for the major events governing the maximum crack length at high augmented strains. Coupling these criteria with models of strain development, temperature distribution, and solidification behavior allows for a priori estimation of the maximum crack length. In the present work, the maximum crack length for a variety of Nb-containing Fe and Ni-based superalloys are estimated by using the above models and criteria, and compared with experimental results. Copyright © 2006 ASM International®.

Our charter at Sandia National Laboratories is to develop technology to reduce the development cost of geothermal drilling. Due to their aggressive penetration rate performance, Polycrystalline Diamond Compact (PDC) bits are of particular interest for this application and they have recently been demonstrated to be capable of drilling hard-rock formations characteristic of geothermal reservoirs. Additionally, oil and gas operators are increasingly forced to extend their drilling targets to include these hard-rock formations as our fossil energy reserves dwindle. However, PDC bits are particularly susceptible to impact-type damage due to the onset of drilling vibrations that can cause bit failure. Bit vibration produces an undulated surface in the rock that in turn produces a time-variant force that feeds back into the vibration of the bit and drillstring. While there is considerable debate in the drilling community regarding the relative significance of the various types of vibrations, self-induced vibrations do occur and can be mathematically predicted if the drill bit, drillstring, and rock type are not correctly matched. One way to alleviate this problem is to insert a vibration absorber into the drillstring. Given the broad range of parameters contributing to bit vibrations, any damper installed in the drillstring should be controllable to give it more dynamic range. We have experimentally demonstrated that a controllable damper can introduce stability in PDC bits drilling hard rock typical of geothermal formations.

Sandia National Laboratories has completed thermal performance testing on the Schott parabolic trough receiver using the LS-2 collector on the Sandia rotating platform at the National Solar Thermal Test Facility in Albuquerque, NM. This testing was funded as part of the US DOE Sun-Lab USA-Trough program. The receiver tested was a new Schott receiver, known as Heat Collector Elements (HCEs). Schott is a new manufacturer of trough HCEs. The Schott HCEs are 4m long; therefore, two were joined and mounted on the LS-2 collector module for the test. The Schott HCE design consists of a 70mm diameter high solar absorptance coated stainless steel (SS) tube encapsulated within a 125mm diameter Pyrex® glass tube with vacuum in the annulus formed between the SS and glass tube to minimize convection heat losses. The Schott HCE design is unique in two regards. First, the bellows used to compensate for the difference in thermal expansion between the metal and glass tube are inside the glass envelope rather than outside. Second, the composition of materials at the glass-to-metal seal has very similar thermal expansion coefficients making the joint less prone to breakage from thermal shock. Sandia National Laboratories provided both the azimuth and elevation collector module tracking systems used during the tests. The test results showed the efficiency of the Schott HCE to be very similar to current HCEs being manufactured by Solel. This testing provided performance verification for the use of Schott tubes with Solargenix trough collector assemblies at currently planned trough power plant projects in Arizona and Nevada. Copyright © 2005 by ASME.

Sandia National Laboratories (Sandia) has an active relationship with the Navajo Nation. Sandia has grown this relationship with through joint formation of strategic multiyear plans oriented toward the development of sustainable Native American renewable energy projects and associated business development. For the last decade, the Navajo Tribal Utility Authority (NTUA) has installed stand-alone photovoltaic (PV) systems on the Navajo Reservation to provide some of its most remote customers with electricity. Sandia and New Mexico State University - Southwest Technology Development Institute's technical assistance supports NTUA as a leader in rural solar electrification, assists NTUA's solar program coordinator to create a sustainable program and conveys NTUA's success in solar to others, including the Department of Energy (DOE). In partnership with DOE's Tribal Energy Program, summer interns' Jennifer Coots (MBA student) and Benjamin Mar (Electrical and Computer Engineering student) prepared case studies that summarize the rural utility's experience with solar electric power.

Noncontinuum gas-phase heat transfer in two microscale geometries is investigated using two computational methods. The motivation is microscale thermal actuation produced by heating-induced expansion of a near-substrate microbeam in air. The first geometry involves a 1-μm microgap filled with gas and bounded by parallel solid slabs. The second geometry involves a heated I-shaped microbeam 2 μm from the adjacent substrate, with gas in between. Two computational methods are applied. The Navier-Stokes slip-jump (NSSJ) method uses continuum heat transfer in the gas, with temperature jumps at boundaries to treat noncontinuum effects. The Direct Simulation Monte Carlo (DSMC) method uses computational molecules to simulate noncontinuum gas behavior accurately. For the microgap, the heat-flux values from both methods are in good agreement for all pressures and accommodation coefficients. For the microbeam, there is comparably good agreement except for cases with low pressures and near-unity accommodation coefficients. The causes of this discrepancy are discussed. Copyright © 2005 by ASME.

A numerical model of the ESR process was used to study the effect of the various process parameters on the resulting temperature profiles, flow field, and pool shapes. The computational domain included the slag and ingot, while the electrode, crucible, and cooling water were considered as external boundary conditions. The model considered heat transfer, fluid flow, solidification, and electromagnetic effects. The predicted pool profiles were compared with experimental results obtained over a range of processing parameters from an industrial-scale 718 alloy ingot. The shape of the melt pool was marked by dropping nickel balls down the annulus of the crucible during melting. Thermocouples placed in the electrode monitored the electrode and slag temperature as melting progressed. The cooling water temperature and flow rate were also monitored. The resulting ingots were sectioned and etched to reveal the ingot macrostructure and the shape of the melt pool. Comparisons of the predicted and experimentally measured pool profiles show excellent agreement. The effect of processing parameters, including the slag cap thickness, on the temperature distribution and flow field are discussed. The results of a sensitivity study of thermophysical properties of the slag are also discussed.

Experimentally measured temperature profiles along the micron-scale beam of a working thermal actuator are reported for the first time. Using a surface Raman scattering technique, temperature measurements are obtained in a noncontact fashion with submicron spatial resolution and to within an uncertainty of better than ± 10 K. The experimental data are used to validate computational predictions of the actuator thermal performance with reasonable agreement between the data and predicted temperatures. Copyright © 2005 by ASME.

The structural characteristics of buttress thread mechanical joints are not well understood and are difficult to accurately model. As an initial step towards understanding the mechanics of the buttress thread, a 2D plane stress model was created. An experimental investigation was conducted to study the compliance, damping characteristics, and stress field in an axial test condition. The compliance and damping were determined experimentally from a steel cross section of a buttress thread. The stress field was visualized using photoelastic techniques. The mechanics study combined with the photoelastic study provided a set of validation data.

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.