Publications

Multichip modules (MCMs) containing power components need a substrate with excellent heat spreading capability to both avoid hot spots and to move dissipation heat toward the system heat sinks. Polycrystalline diamond is an excellent MCM heat spreading substrate but remains several orders of magnitude too expensive and somewhat more difficult to process than conventional mother-board materials. Today`s power MCMs concentrate on moderately priced silicon wafers and aluminum nitride ceramic with their improved thermal conductivity and good thermal expansion match to power semiconductor components in comparison to traditional alumina and printed wiring board materials. However, even silicon and AlN substrates are thermally challenged by designers needs. The authors report on the integral fabrication of micro-heat pipes embedded in silicon MCM substrates (5 x 5 cm) by the use of micromachined capillary wick structures and hermetic micro-cavities. This passive microstructure results in more than a 5 times improvement in heat spreading capability of the silicon MCM substrate over a large range of power densities and operating temperatures. Thus diamond-like cooling is possible at silicon prices.

Detecting object boundaries in the presence of cast shadows is a difficult task for machine vision systems. A new edge detector is presented which responds to shadow penumbras and abrupt object edges with distinguishable signals. The detector requires the use of spatially extended light sources and sufficient video resolution to resolve the shadow penumbras of interest. Detection of high frequency noise is suppressed without requiring image-dependent adjustment of signal thresholds. The ability of the edge operator to distinguish shadow penumbras from abrupt object boundaries while suppressing responses to high frequency noise and texture is illustrated with idealized shadow and object edge intensity profiles. Selective detection of object boundaries in a video scene with a cast shadow has also been demonstrated with this operator.

Modular fixturing kits are precisely machined sets of components used for flexible, short-turnaround construction of fixtures for a variety of manufacturing purposes. A modular vise is a parallel-jaw vise, where each jaw is a modular fixture plate with a regular grid of precisely positioned holes. A modular vise can be used to locate and hold parts for machining, assembly, and inspection tasks. To fixture a part, one places pins in some of the holes so that when the vise is closed, the part is reliably located and completely constrained. The modular vise concept can be adapted easily to the design of modular parallel-jaw grippers for robots. By attaching a grid plate to each jaw of a parallel-jaw gripper, the authors gain the ability to easily construct high-quality grasps for a wide variety of parts from a standard set of hardware. Wallack and Canny developed a previous algorithm for planning planar grasp configurations for the modular vise. In this paper, the authors expand this work to produce a 3-d fixture/gripper design tool. They describe several analyses added to the planar algorithm to improve its utility, including a three-dimensional grasp quality metric based on geometric and force information, three-dimensional geometric loading analysis, and inter-gripper interference analysis to determine the compatibility of multiple grasps for handing the part from one gripper to another. Finally, the authors describe two applications which combine the utility of modular vise-style grasping with inter-gripper interference: The first is the design of a flexible part-handling subsystem for a part cleaning workcell under development at Sandia National Laboratories; the second is the automatic design of grippers that support the assembly of multiple products on a single assembly line.

The goal of the Modular Weapon Control Unit (MWCU) program was to design and develop a reconfigurable weapon controller (programmer/sequencer) that can be adapted to different weapon systems based on the particular requirements for that system. Programmers from previous systems are conceptually the same and perform similar tasks. Because of this commonality and the amount of re-engineering necessary with the advent of every new design, the idea of a modular, adaptable system has emerged. Also, the controller can be used in more than one application for a specific weapon system. Functionality has been divided into a Processor Module (PM) and an Input/Output Module (IOM). The PM will handle all operations that require calculations, memory, and timing. The IOM will handle interfaces to the rest of the system, input level shifting, output drive capability, and detection of interrupt conditions. Configuration flexibility is achieved in two ways. First, the operation of the PM is determined by a surface mount Read-Only Memory (ROM). Other surface-mount components can be added or neglected as necessary for functionality. Second, IOMs consist of configurable input buffers, configurable output drivers, and configurable interrupt generation. Further, these modules can be added singly or in groups to a Processor Module to achieve the required I/O configuration. The culmination of this LDRD was the building of both Processor Module and Input/Output Module. The MWCU was chosen as a test system to evaluate Low-Temperature Co-fired Ceramic (LTCC) technology, desirable for high component density and good thermal characteristics.

A series of three 18.9 m diameter JP-4 pool fire experiments with a large (2.1 m X 4.6 m), flat plate calorimeter adjacent to the fuel pool were recently performed. The objectives of these experiments were to: (1) gain a better understanding of fire phenomenology, (2) provide empirical input parameter estimates for simplified, deterministic Risk Assessment Compatible Fire Models (RACFMs), (3) assist in continuing fire field model code validation and development, and (4) enhance the data base of fire temperature and heat flux to object distributions. Due to different wind conditions during each experiment, data were obtained for conditions where the plate was not engulfed, fully-engulfed and partially engulfed by the continuous flame zone. Results include the heat flux distribution to the plate and flame thermocouple temperatures in the vicinity of the plate and at two cross sections within the lower region of the continuous flame zone. The results emphasize the importance of radiative coupling (i.e. the cooling of the flames by a thermally massive object) and convective coupling (including object-induced turbulence and object/wind/flame interactions) in determining the heat flux from a fire to an object. The formation of a secondary flame zone on an object adjacent to a fire via convective coupling (which increases the heat flux by a factor of two) is shown to be possible when the object is located within a distance equal to the object width from the fire.

This study involved the evaluation and documentation of cases in which petroleum wellbores were enlarged beyond the nominal hole diameter as a consequence of erosion during exploratory drilling, particularly as a function of gas flow into the wellbore during blowout conditions. A primary objective was to identify analogs to potential wellbore enlargement at the Waste Isolation Pilot Plant (WIPP) during inadvertent human intrusion. Secondary objectives were to identify drilling scenarios associated with enlargement, determine the physical extent of enlargement, and establish the physical properties of the formation in which the enlargement occurred. No analogs of sufficient quality to establish quantitative limits on wellbore enlargement at the WIPP disposal system were identified. However, some information was obtained regarding the frequency of petroleum well blowouts and the likelihood that such blowouts would bridge downhole, self-limiting the surface release of disposal-system material. Further work would be necessary, however, to determine the conditions under which bridging could occur and the extent to which the bridging might be applicable to WIPP. In addition, data on casing sizes of petroleum boreholes in the WIPP vicinity support the use of a 12-{1/4} inch borehole size in WIPP performance assessment calculations. Finally, although data are limited, there was no evidence of significant wellbore enlargement in any of three blowouts that occur-red in wellbores in the Delaware Basin (South Culebra Bluff Unit No. 1, Energy Research and Development Administration (ERDA) 6, and WIPP 12).

This report contains a condensed listing of Waste Isolation Pilot Plant (WIPP) project surface boreholes drilled for the purpose of site selection and characterization through 31 December 1995. The US Department of Energy (DOE) sponsored the drilling activities, which were conducted primarily by Sandia National Laboratories. The listing provides physical attributes such as location (township, range, section, and state-plane coordinates), elevation, and total borehole depth, as well as the purpose for the borehole, drilling dates, and information about extracted cores. The report also presents the hole status (plugged, testing, monitoring, etc.) and includes salient findings and references. Maps with borehole locations and times-of-drilling charts are included.

Energetic materials, such as high explosives, propellants and ballotechnics, are widely used as energy sources in the design of numerous devices, components and processes. Although most energetic materials are selected for safe operation, their high energy densities have the potential for inadvertent initiation and subsequent powerful energy transformations. This potential for damage or injury places a heavy burden on careful analysis of safety issues as part of the design process. As a result, considerable effort has been devoted to empirical testing of initiation conditions, and development of scientific models of initiation processes that have been incorporated into computer models for numerical simulation of initiation of reaction. Nevertheless, in many cases, there is still only rudimentary understanding of the processes of initiation. Mechanochemical processes are perhaps the least understood of the various excitation mechanisms. In these energy transformation processes mechanical stimuli lead directly to initiation and substantial reaction under conditions not thought to be capable of reaction. There are no established scientific models of the initiation of mechanochemical reactions in energetic materials. Mechanochemical reactions can be initiated by enhanced solid state chemical reactivity, changes in reactant configuration, and localization of initiation energy. Such solid state reactions are difficult to understand, either empirically or scientifically, as they are inherently nonequilibrium processes; scientific models currently used assume equilibrium thermochemical conditions and materials behaviors. The present work was undertaken as a first step in developing a scientific basis for prediction of the initiation of mechanochemical processes in high energy density solids.

Networks at major computational organizations are becoming increasingly complex. The introduction of large massively parallel computers and supercomputers with gigabyte memories are requiring greater and greater bandwidth for network data transfers to widely dispersed clients. For networks to provide adequate data transfer services to high performance computers and remote users connected to them, the networking components must be optimized from a combination of internal and external performance criteria. This paper describes research done at Sandia National Laboratories to model network data services and to visualize the flow of data from source to sink when using the data services.

The Hierarchical High-Performance Storage System (HPSS) Testbed project at Sandia National Laboratories was part of a research collaboration between industry, national research centers, and national laboratories to develop mass storage system software that would scale to meet the capacity and performance required by supercomputer and massively parallel computational environments. This report describes the software that was developed within this collaboration as a result of a cooperative research and development agreement between Sandia National Laboratories and International Business Machines (IBM) Corporation, Government Systems.

We report results in three areas of research relevant to the fabrication of a wide range of optoelectronic devices: The development of a new x-ray diffraction technique that can be used to rapidly determine the optimal period of a strained layer superlattice to maximize the dislocation filtering; The optimal MBE growth parameters for the growth of CdTe on GaAs(211); The determination of the relative efficiency of dislocation filtering in the (211) and (100) orientations; and The surface quality of InSb grown by MOCVD on InSb substrates is affected by the misorientation of the substrate.

This report describes the information model that was jointly developed as part of two FY93 LDRDs: (1) Information Integration for Data Fusion, and (2) Interactive On-Site Inspection System: An Information System to Support Arms Control Inspections. This report describes the purpose and scope of the two LDRD projects and reviews the prototype development approach, including the use of a GIS. Section 2 describes the information modeling methodology. Section 3 provides a conceptual data dictionary for the OSIS (On-Site Information System) model, which can be used in conjunction with the detailed information model provided in the Appendix. Section 4 discussions the lessons learned from the modeling and the prototype. Section 5 identifies the next steps--two alternate paths for future development. The long-term purpose of the On-Site Inspection LDRD was to show the benefits of an information system to support a wide range of on-site inspection activities for both offensive and defensive inspections. The database structure and the information system would support inspection activities under nuclear, chemical, biological, and conventional arms control treaties. This would allow a common database to be shared for all types of inspections, providing much greater cross-treaty synergy.

An improved capability for subsurface structure detection is needed to support military and nonproliferation requirements for inspection and for surveillance of activities of threatening nations. As part of the DOE/NN-20 program to apply geophysical methods to detect and characterize underground facilities, Sandia National Laboratories (SNL) initiated an electromagnetic induction (EMI) project to evaluate low frequency electromagnetic (EM) techniques for subsurface structure detection. Low frequency, in this case, extended from kilohertz to hundreds of kilohertz. An EMI survey procedure had already been developed for borehole imaging of coal seams and had successfully been applied in a surface mode to detect a drug smuggling tunnel. The SNL project has focused on building upon the success of that procedure and applying it to surface and low altitude airborne platforms. Part of SNL`s work has focused on improving that technology through improved hardware and data processing. The improved hardware development has been performed utilizing Laboratory Directed Research and Development (LDRD) funding. In addition, SNL`s effort focused on: (1) improvements in modeling of the basic geophysics of the illuminating electromagnetic field and its coupling to the underground target (partially funded using LDRD funds) and (2) development of techniques for phase-based and multi-frequency processing and spatial processing to support subsurface target detection and characterization. The products of this project are: (1) an evaluation of an improved EM gradiometer, (2) an improved gradiometer concept for possible future development, (3) an improved modeling capability, (4) demonstration of an EM wave migration method for target recognition, and a demonstration that the technology is capable of detecting targets to depths exceeding 25 meters.

Data fusion has been identified by the Department of Defense as a critical technology for the U.S. defense industry. Data fusion requires combining expertise in two areas - sensors and information integration. Although data fusion is a rapidly growing area, there is little synergy and use of common, reusable, and/or tailorable objects and models, especially across different disciplines. The Laboratory-Directed Research and Development project had two purposes: to see if a natural language-based information modeling methodology could be used for data fusion problems, and if so, to determine whether this methodology would help identify commonalities across areas and achieve greater synergy. The project confirmed both of the initial hypotheses: that the natural language-based information modeling methodology could be used effectively in data fusion areas and that commonalities could be found that would allow synergy across various data fusion areas. The project found five common objects that are the basis for all of the data fusion areas examined: targets, behaviors, environments, signatures, and sensors. Many of the objects and the specific facts related to these objects were common across several areas and could easily be reused. In some cases, even the terminology remained the same. In other cases, different areas had their own terminology, but the concepts were the same. This commonality is important with the growing use of multisensor data fusion. Data fusion is much more difficult if each type of sensor uses its own objects and models rather than building on a common set. This report introduces data fusion, discusses how the synergy generated by this LDRD would have benefited an earlier successful project and contains a summary information model from that project, describes a preliminary management information model, and explains how information integration can facilitate cross-treaty synergy for various arms control treaties.

Rock cores from drillholes UE25-NRG-4, USW-NRG-6, USW-NRG-7, and USW-SD-9 containing natural fractures were obtained from the Sample Management Facility at Yucca Mountain, Nevada. All recoverable fractures were sheared at constant normal stresses from 2.5 to 15 MPa, in the as-received condition (air-dry). Detailed profilometer data were collected from each fracture surface before testing. The tests yielded the normal closure as a function of normal stress, and the shear stress and dilation as functions of shear offset. The constitutive properties obtained from these stress-displacement relations were: normal stiffness, shear stiffness, shear strength, and dilation angle at peak shear stress. Shear strength plotted against normal stress for four thermomechanical units shows that friction angle varies from 370 to 460 and cohesion varies from 0.02 to 1.71 MPa.

This report provides an overview of the work completed for a portion of the User Interface Testbed for Technology Packaging (UseIT) project. The authors present software methods for programming systems to record and view interactions with a graphical user interface. A brief description of the human factors design process is presented. The software methods exploit features available in the X Window System and the operating system for Windows{trademark} 95 and Windows{trademark} NT{reg_sign}.

Work on thermionic nuclear power systems has been performed in Russia within the framework of the TOPAZ reactor program since the early 1960s. In the TOPAZ in-core thermionic convertor reactor design, the fuel element`s cladding is also the thermionic convertor`s emitter. Deformation of the emitter can lead to short-circuiting and is the primary cause of premature TRC failure. Such deformation can be the result of fuel swelling, thermocycling, or increased unilateral pressure on the emitter due to the release of gaseous fission products. Much of the work on TRCs has concentrated on preventing or mitigating emitter deformation by improving the following materials and structures: nuclear fuel; emitter materials; electrical insulators; moderator and reflector materials; and gas-exhaust device. In addition, considerable effort has been directed toward the development of experimental techniques that accurately mimic operational conditions and toward the creation of analytical and numerical models that allow operational conditions and behavior to be predicted without the expense and time demands of in-pile tests. New and modified materials and structures for the cores of thermionic NPSs and new fabrication processes for the materials have ensured the possibility of creating thermionic NPSs for a wide range of powers, from tens to several hundreds of kilowatts, with life spans of 5 to 10 years.

This report summarizes the work performed under the Sandia Laboratory Directed Research and Development (LDRD) project ``Optical Diagnostics for Turbulent and Multiphase Flows.`` Advanced optical diagnostics have been investigated and developed for flow field measurements, including capabilities for measurement in turbulent, multiphase, and heated flows. Particle Image Velocimetry (PIV) includes several techniques for measurement of instantaneous flow field velocities and associated turbulence quantities. Nonlinear photorefractive optical materials have been investigated for the possibility of measuring turbulence quantities (turbulent spectrum) more directly. The two-dimensional PIV techniques developed under this LDRD were shown to work well, and were compared with more traditional laser Doppler velocimetry (LDV). Three-dimensional PIV techniques were developed and tested, but due to several experimental difficulties were not as successful. The photorefractive techniques were tested, and both potential capabilities and possible problem areas were elucidated.

This Phase 1 report documents the results of one of the subtasks that was initiated under the joint Department of Energy (DOE)/Department of Defense (DoD) Memorandum of Understanding (MOU) for Countermine Warfare. The development of a foam that can neutralize mines and barriers and allow the safe passage of amphibious landing craft and vehicles was the objective of this subtask of the Sea Mine Countermeasures Technology program. This phase of the program concentrated on laboratory characterization of foam properties and field experiments with prefabricated foam blocks to determine the capability of RPF to adequately carry military traffic. It also established the flammability characteristics of the material under simulated operational conditions, extended the understanding of explosive cavity formation in RPF to include surface explosions, established the tolerance to typical military fluids, and the response to bullet impact. Many of the basic analyses required to establish the operational concept are reported. The initial field experiments were conducted at the Energetic Materials Research and Testing Center (EMRTC) of the New Mexico Institute of Mining and Technology, Socorro, NM in November 1995 through February 1996.

A tool using a continuous electromagnetic wave from a transverse magnetic-dipole source with a coaxial electric-dipole receiver is outlined for the detection of external sidewall cracks in boiler tubes. A numerical study of the distribution of the fields shows that the direct transmission from the source to the receiver is reduced from that in free space. Further, if the diameter of the receiver dipole is made sufficiently small, it should be possible to detect cracks with a scattering loss of up to 40dB in thin-walled boiler tubes.

Wireline core drilling, increasingly used for geothermal exploration, employs a core-tube to capture a rock core sample during drilling. Three types of core-tube data loggers (CTDL) have been built and tested to date by Sandia national Laboratories. They are: (1) temperature-only logger, (2) temperature/inclinometer logger and (3) heat-shielded temperature/inclinometer logger. All were tested during core drilling operations using standard wireline diamond core drilling equipment. While these tools are designed for core-tube deployment, the tool lends itself to be adapted to other drilling modes and equipment. Topics covered in this paper include: (1) description on how the CTDLs are implemented, (2) the components of the system, (3) the type of data one can expect from this type of tool, (4) lessons learned, (5) comparison to its counterpart and (6) future work.

The author presents a final report on a Laboratory-Directed Research and Development (LDRD) project, Innovative Computing for Diagnoses from Medical, Magnetic-Resonance Imaging, performed during fiscal years 1992 and 1993. The project defined a role for high-performance computing in surgery: the supercomputer can automatically summarize the three-dimensional extents of lesions and other clinically-relevant structures, and can deliver these summaries to workstation-based, augmented-reality environments at the clinical site. The author developed methods and software to make these summaries from the digital data already acquired using clinical, magnetic-resonance machines. In joint work with Albuquerque`s Department of Veterans Affairs Hospital, the author applied this work, and obtained a basis for planning, for rehearsal, and for guidance during surgery.

As part of the Advanced Technologies for International and Intermodal Ports of Entry (ATIPE) Project, a diverse group of stakeholders was engaged to help identify problems experienced at inland international border crossings, particularly those at the US-Mexican border. The fundamental issue at international ports of entry is reducing transit time through the required documentation and inspection processes. Examples of other issues or problems, typically manifested as time delays at border crossings, repeatedly mentioned by stakeholders include: (1) lack of document standardization; (2) failure to standardize inspection processes; (3) inadequate information and communications systems; (4) manual fee and tariff collection; (5) inconsistency of processes and procedures; and (6) suboptimal cooperation among governmental agencies. Most of these issues can be addressed to some extent by the development of advanced technologies with the objective of allowing ports of entry to become more efficient while being more effective. Three categories of technologies were unambiguously of high priority to port of entry stakeholders: (1) automated documentation; (2) systems integration; and (3) vehicle and cargo tracking. Together, these technologies represent many of the technical components necessary for pre-clearance of freight approaching international ports of entry. Integration of vehicle and cargo tracking systems with port of entry information and communications systems, as well as existing industry legacy systems, should further enable border crossings to be accomplished consistently with optimal processing times.

During July-November, 1995, Sandia National Laboratories, in cooperation with CE Exploration, drilled a 5,360 foot exploratory slimhole (3.85 inches diameter) in the Newberry Known Geothermal Resource Area (KGRA) near Bend, Oregon. This well was part of Sandia`s program to evaluate slimholes as a geothermal exploration tool. During and after drilling the authors performed numerous temperature logs, and at the completion of drilling attempted to perform injection tests. In addition to these measurements, the well`s data set includes: over 4,000 feet of continuous core (with detailed log); daily drilling reports from Sandia and from drilling contractor personnel; daily drilling fluid record; and comparative data from other wells drilled in the Newberry KGRA.

A high temperature spectral gamma tool has been designed and built for use in small-diameter geothermal exploration wells. Several engineering judgments are discussed regarding operating parameters, well model selection, and signal processing. An actual well log at elevated temperatures is given with spectral gamma reading showing repeatability.