Publications

By predicting the total life-cycle cost of owning and operating production equipment, it becomes possible for processors to make accurate and intelligent decisions regarding major capitol equipment investments as well as determining the most cost effective manufacturing processes and environments. Cost of Ownership (COO) is a decision making technique based on inputting the total costs of acquiring, operating and maintaining production equipment. All quantitative economic and production data can be modeled and processed using COO software programs such as the Cost of Ownership Luminator program TWO COOL{trademark}. This report investigated the Cost of Ownership differences between the current state-of-the-art solder ball attachment process and a prototype solder jetting process developed by Sandia National Laboratories. The prototype jetting process is a novel and unique approach to address the anticipated high rate ball grid array (BGA) production requirements currently forecasted for the next decade. The jetting process, which is both economically and environmentally attractive eliminates the solder sphere fabrication step, the solder flux application step as well as the furnace reflow and post cleaning operations.

A comprehensive collection of scenarios is presented that connect initiating tectonic events with radionuclide releases by logical and physically possible combinations or sequences of features, events and processes. The initiating tectonic events include both discrete faulting and distributed rock deformation developed through the repository and adjacent to it, as well as earthquake-induced ground motion and changes in tectonic stress at the site. The effects of these tectonic events include impacts on the engineered-barrier system, such as container rupture and failure of repository tunnels. These effects also include a wide range of hydrologic effects such as changes in pathways and flow rates in the unsaturated and saturated zones, changes in the water-table configuration, and in the development of perched-water systems. These scenarios are intended go guide performance-assessment analyses and to assist principal investigators in how essential field, laboratory, and calculational studies are used. This suite of scenarios will help ensure that all important aspects of the system disturbance related to a tectonic scenario are captured in numerical analyses. It also provides a record of all options considered by project analysts to provide documentation required for licensing agreement. The final portion of this report discusses issues remaining to be addressed with respect to tectonic activity. 105 refs.

Smoke can adversely affect digital electronics; in the short term, it can lead to circuit bridging and in the long term to corrosion of metal parts. This report is a summary of the work to date and component-level tests by Sandia National Laboratories for the Nuclear Regulatory Commission to determine the impact of smoke on digital instrumentation and control equipment. The component tests focused on short-term effects such as circuit bridging in typical components and the factors that can influence how much the smoke will affect them. These factors include the component technology and packaging, physical board protection, and environmental conditions such as the amount of smoke, temperature of burn, and humidity level. The likelihood of circuit bridging was tested by measuring leakage currents and converting those currents to resistance in ohms. Hermetically sealed ceramic packages were more resistant to smoke than plastic packages. Coating the boards with an acrylic spray provided some protection against circuit bridging. The smoke generation factors that affect the resistance the most are humidity, fuel level, and burn temperature. The use of CO{sub 2} as a fire suppressant, the presence of galvanic metal, and the presence of PVC did not significantly affect the outcome of these results.

Findings from a four-year study by an international benchmarking group in the comparison of computational methods for evaluating burnup credit in criticality safety analyses are presented in this paper. Approximately 20 participants from 11 countries have provided results for most problems. Four detailed benchmark problems for Pressurized Water Reactor (PWR) fuel have been completed and are summarized in this paper. Preliminary results from current work addressing burnup credit for Boiling Water Reactor (BWR) fuel will also be discussed as well as planned activities for additional benchmarks including Mixed-Oxide (MOX) fuels, subcritical benchmarks, international databases, and other activities.

No abstract available.

The U.S. Department of Energy`s (DOE) Yucca Mountain Site Characterization Project (YMP) is studying Yucca Mountain in southwestern Nevada as a potential site for a high-level nuclear waste repository. Site characterization will be facilitated by the construction of an Exploratory Studies Facility (ESF). The ESF and potential repository will be excavated from both nonwelded and welded ashflow tuff with varying rock quality (degree of welding, rock mass strength, etc.) and fault and fracture characteristics. Design concerns for the construction of these facilities include the integrity of the structure during underground testing operations and, if it occurs, the emplacement and storage of high-level nuclear waste which could increase the local temperatures in the underground rock mass to as high as 300{degrees}C. Because of the associated issues regarding personnel and long-term environmental safety, sophisticated jointed rock mass models will be required to provide a high degree of confidence for decisions regarding the design, site characterization, and licensing of such facilities. The objective of the work documented in this report is to perform code validation calculations for three rock-mass computer models. The three rock-mass computer models used for this report are the discrete element code UDEC, Version 1.82; and the finite element continuum joint models JAC2D Version 5.10 and JAS3D Version 1.1. The rock mass behavior predicted by the models are compared to the results of laboratory experiments on layered polycarbonate (Lexan) and granite plate experiments. These experiments examine the rock mass behavior of well-defined jointed rock structures or models of jointed structures under uniaxial and biaxial loading. The laboratory environment allows control over the boundary conditions, material properties, and quality and quantity of the data obtained.

This report describes activities completed in August 1996 under a Cooperative Research and Development Agreement (CRADA) between Sandia National Laboratories and General Motors which began in April 1993 and was later expanded in January 1994 to include Ford and Chrysler under the Low Emission Partnership (LEP). The tasks within this effort (CRADA SC93/01155) included the evaluation of hydrous metal oxide materials as catalyst supports for the abatement of nitrogen oxides in lean-burn automotive exhaust catalyst applications.

Fracture and matrix properties in a sequence of unsaturated, welded tuffs at Yucca Mountain, Nevada, are modeled in two-dimensional cross-sections through geostatistical simulation. In the absence of large amounts of sample data, an n interpretive, deterministic, stratigraphic model is coupled with a gaussian simulation algorithm to constrain realizations of both matrix porosity and fracture frequency. Use of the deterministic, stratigraphic model imposes scientific judgment, in the form of a conceptual geologic model, onto the property realizations. Linear coregionalization and a regression relationship between matrix porosity and matrix hydraulic conductivity are used to generate realizations of matrix hydraulic conductivity. Fracture-frequency simulations conditioned on the stratigraphic model represent one class of fractures (cooling fractures) in the conceptual model of the geology. A second class of fractures (tectonic fractures) is conceptualized as fractures that cut across strata vertically and includes discrete features such as fault zones. Indicator geostatistical simulation provides locations of this second class of fractures. The indicator realizations are combined with the realizations of fracture spacing to create realizations of fracture frequency that are a combination of both classes of fractures. Evaluations of the resulting realizations include comparing vertical profiles of rock properties within the model to those observed in boreholes and checking intra-unit property distributions against collected data. Geostatistical simulation provides an efficient means of addressing spatial uncertainty in dual continuum rock properties.

Advantages in transient ionizing and single-event upset (SEU) radiation hardness of silicon-on-insulator (SOI) technology spurred much of its early development. Both of these advantages are a direct result of the reduced charge collection volume inherent to SOI technology. The fact that SOI transistor structures do not include parasitic n-p-n-p paths makes them immune to latchup. Even though considerable improvement in transient and single-event radiation hardness can be obtained by using SOI technology, there are some attributes of SOI devices and circuits that tend to limit their overall hardness. These attributes include the bipolar effect that can ultimately reduce the hardness of SOI ICs to SEU and transient ionizing radiation, and charge buildup in buried and sidewall oxides that can degrade the total-dose hardness of SOI devices. Nevertheless, high-performance SOI circuits can be fabricated that are hardened to both space and nuclear radiation environments, and radiation-hardened systems remain an active market for SOI devices. The effects of radiation on SOI MOS devices are reviewed.

In 1991, the Department of Energy initiated the Advanced Liquefaction Concepts Program to promote the development of new and emerging technology that has potential to reduce the cost of producing liquid fuels by direct coal liquefaction. Laboratory research performed by researchers at CAER, CONSOL, Sandia, and LDP Associates in Phase I is being developed further and tested at the bench scale at HTI. HTI Run ALC-1, conducted in the spring of 1996, was the first of four planned tests. In Run ALC-1, feed coal ash reduction (coal cleaning) by oil agglomeration, and recycle solvent quality improvement through dewaxing and hydrotreatment of the recycle distillate were evaluated. HTI`s bench liquefaction Run ALC-1 consisted of 25 days of operation. Major accomplishments were: 1) oil agglomeration reduced the ash content of Black Thunder Mine coal by 40%, from 5.5% to 3.3%; 2) excellent coal conversion of 98% was obtained with oil agglomerated coal, about 3% higher than the raw Black Thunder Mine coal, increasing the potential product yield by 2-3% on an MAF coal basis; 3) agglomerates were liquefied with no handling problems; 4) fresh catalyst make-up rate was decreased by 30%, with no apparent detrimental operating characteristics, both when agglomerates were fed and when raw coal was fed (with solvent dewaxing and hydrotreating); 5) recycle solvent treatment by dewaxing and hydrotreating was demonstrated, but steady-state operation was not achieved; and 6) there was some success in achieving extinction recycle of the heaviest liquid products. Performance data have not been finalized; they will be available for full evaluation in the new future.

Systems and devices that are controlled remotely are becoming more common in security systems in the US Air Force and other government agencies to provide protection of valuable assets. These systems reduce the number of needed personnel while still providing a high level of protection. However, each remotely controlled device usually has its own communication protocol. This limits the ability to change devices without changing the system that provides the communications control to the device. Sandia is pursuing a standard protocol that can be used to communicate with the different devices currently in use, or may be used in the future, in the US Air Force and other government agencies throughout the security community. Devices to be controlled include intelligent pan/tilt mounts, day/night video cameras., thermal imaging cameras, and remote data processors. Important features of this protocol include the ability to send messages of varying length, identify the sender, and more importantly, control remote data processors. As camera and digital signal processor (DSP) use expands, the DSP will begin to reside in the camera itself. The DSP can be used to provide auto-focus, frame-to- frame image registration, video motion detection (VMD), target detection, tracking, image compression, and many other functions. With the serial data control link, the actual DSP software can be updated or changed as required. Coaxial video cables may become obsolete once a compression algorithm is established in the DSP. This paper describes the proposed public domain protocol, features, and examples of use. The authors hope to elicit comments from security technology developers regarding format and use of remotely controlled automated assessment devices. 2 figs., 1 tab.

A {ital q}-vector of responses, y, is related to a {ital p}-vector of explanatory variables, x, through a causal linear model. In analytical chemistry, y and x might represent the spectrum and associated set of constituent concentrations of a multicomponent sample which are related through Beer`s law. The model parameters are estimated during a calibration process in which both x and y are available for a number of observations (samples/specimens) which are collectively referred to as the calibration set. For new observations, the fitted calibration model is then used as the basis for predicting the unknown values of the new x`s (concentrations) form the associated new y`s (spectra) in the prediction set. This prediction procedure can be viewed as parameter estimation in an errors-in-variables (EIV) framework. In addition to providing a basis for simultaneous inference about the new x`s, consideration of the EIV framework yields a number of insights relating to the design and execution of calibration studies. A particularly interesting result is that predictions of the new x`s for individual samples can be improved by using seemingly unrelated information contained in the y`s from the other members of the prediction set. Furthermore, motivated by this EIV analysis, this result can be extended beyond the causal modeling context to a broader range of applications of multivariate calibration which involve the use of principal components regression.

We have developed a two-dimensional Shack-Hartman wavefront sensor that uses binary optic lenslet arrays to directly measure the wavefront slope (phase gradient) and amplitude of the laser beam. This sensor uses an array of lenslets that dissects the beam into a number of samples. The focal spot location of each of these lenslets (measured by a CCD camera) is related to the incoming wavefront slope over the lenslet. By integrating these measurements over the laser aperture, the wavefront or phase distribution can be determined. Since the power focused by each lenslet is also easily determined, this allows a complete measurement of the intensity and phase distribution of the laser beam. Furthermore, all the information is obtained in a single measurement. Knowing the complete scalar field of the beam allows the detailed prediction of the actual beam`s characteristics along its propagation path. In particular, the space- beamwidth product M{sup 2}, can be obtained in a single measurement. The intensity and phase information can be used in concert with information about other elements in the optical train to predict the beam size, shape, phase and other characteristics anywhere in the optical train. We present preliminary measurements of an Ar{sup +} laser beam and associated M{sup 2} calculations.

The quest for fabricating complex metal parts rapidly and with minimal cost has brought rapid prototyping (RP) processes to the forefront of the investment casting industry. Relatively recent advances in DTM Corporation`s selective laser sintering (SLS) and 3D Systems stereolithography (SL) processes have had a significant impact on the overall quality of patterns produced using these rapid prototyping processes. Sandia National Laboratories uses patterns generated from rapid prototyping processes to reduce the cycle time and cost of fabricating prototype and small lot production parts in support of a program called FASTCAST. The SLS process is used to fabricate patterns from materials such as investment casting wax, polycarbonate, and a new material called TrueForm PM{trademark}. With the timely introduction of each of these materials, the quality of patterns fabricated has improved. The development and implementation of SL QuickCast{trademark} software has enabled this process to produce highly accurate patterns for use in investment casting. This paper focuses on the successes with these new pattern materials and the infrastructure required to cast rapid prototyping patterns successfully. In addition, a brief overview of other applications of rapid prototyping at Sandia will be discussed.

Resistance degradation in PZT thin-film capacitors has been studied as a function of applied voltage, temperature, and film composition. It is found that the mean-time-to-failure (life-time or t{sub f}) of the capacitors shows a power law dependence on applied voltage of he form t{sub f} {proportional_to} V{sup {minus}n} (n {approximately} 4--5). The capacitor life-time also exhibits a temperature dependence of the form t{sub f} {proportional_to} exp(E{sub a}/kT), with an activation energy of {approximately} 0.8 eV. The steady-state leakage current in these samples appears to be bulk controlled. The voltage, temperature, and polarity dependence of the leakage current collectively suggest a leakage current mechanism most similar to a Frenkel-Poole process. The life-time and leakage current of the Nb-doped PZT films are superior to the undoped PZT films. This result can be explained based on the point-defect chemistry of the PZT system. Finally, the results indicate that the Nb-doped PZT films meet the essential requirements for decoupling capacitor applications.

First-principles density functional calculations and corresponding experimental results underline the importance of basic chemical concepts, such as coordination, valence saturation and promotion-hybridization energetics, in understanding bonding and diffusion of atoms at and on metal surfaces. Several examples are reviewed, including outer-layer relaxations of clean hcp(0001) surfaces, liquid-metal-embrittlement energetics, separation energies of metal-adatom dimers, concerted substitutional self-diffusion on fcc(001) surfaces, and adsorption and diffusion barrier sites for adatoms near steps.

The Department of Defense (DoD) operates hundreds of test, evaluation, and training facilities across the US and abroad. Due to the nature of their missions, these facilities are often remote and isolated from the utility grid. The preferred choice for power at these facilities has historically been manned diesel generators. The DoD Photovoltaic Review Committee, estimates that on the order of 350 million gallons of diesel fuel is burned each year to generate the 2000 GWh of electricity required to operate these remote military facilities. Other federal agencies, including the National Park Service and the USDA Forest Service use diesel generators for remote power needs as well. The generation of power diesel generators is both expensive and detrimental to the environment. The augmentation of power from diesel generators with power processing and battery energy storage enhances the efficiency and utilization of the generator resulting in lower fuel consumption and lower generator run- time in proportion to the amount of renewables added. The hybrid technology can both reduce the cost of power and reduce environmental degradation at remote DoD facilities. This paper describes the expected performance and economics of photovoltaic/diesel hybrid systems. Capabilities and status of systems now being installed at DoD facilities are presented along with financing mechanisms available within DoD.

Sandia National Laboratories developed a process to identify and remove the hazardous sub-components from dismantled weapons components utilizing real-time radiography and abrasive water-jet cutting. The components were then crushed, granulated, screened, and separated into an aluminium and a precious-and-base-metals fraction using air-tables. Plastics were further cleaned for disposal as non- hazardous waste.

Solid free form fabrication is one of the fastest growing automated manufacturing technologies that has significantly impacted the length of time between initial concept and actual part fabrication. Starting with CAD renditions of new components, several techniques such as stereolithography and selective laser sintering are being used to fabricate highly accurate complex three-dimensional concept models using polymeric materials. Coupled with investment casting techniques, sacrificial polymeric objects are used to minimize costs and time to fabricate tooling used to make complex metal castings. This paper will describe recent developments in a new technology, known as LENS{sup {trademark}} (Laser Engineered Net Shaping), to fabricate metal components directly from CAD solid models and thus further reduce the lead times for metal part fabrication. In a manner analogous to stereolithography or selective sintering, the LENS{sup {trademark}} process builds metal parts line by line and layer by layer. Metal particles are injected into a laser beam, where they are melted and deposited onto a substrate as a miniature weld pool. The trace of the laser beam on the substrate is driven by the definition of CAD models until the desired net-shaped densified metal component is produced.

The international scientific community has long had an interest in determining methods by which information regarding nuclear waste repositories, and the inherent danger to humanity, could be passed from generation to generation and society to society. Because nuclear waste will remain radioactive for thousands of years future generations must be warned of the dangers thus eliminating intentional or inadvertent intrusion. Member States of the IAEA have determined that the principle safety of such sites must not rely solely on long term institutional arrangements for the retention of information. It is believed that repository siting, design, operation and postoperation information should be gathered, managed and retained so that this information remains accessible to future societies over a very long period of time. The radionuclide life is 10,000 years; thus the retention of information continues beyond current societies, cultures and languages, and must be continually migrated to new retrieval technologies to assure access.

A great deal has been written about the history of science in America since World War II. Much of that work has explored the government`s research and development establishment, focusing on the scientific community immediately after the war. It is generally argued that the apparent triumphs of the huge and expensive wartime research and development projects gave rise to a belief that scientific resources should be nurtured and kept on hand - ready to provide service in an emergency. The Cold War drive for more and better weapons further fed this belief, leading to a massive system of national laboratories, military laboratories, and defense industries. The science of this complex is built on extensive financial support, the central strategy of which is that by steadily, and occasionally even lavishly funding large research programs, you will have a constant stream of scientific ideas that can be applied to national security purposes. What is true of science, is also true, in slightly modified form, of postwar engineering. The story I want to tell you today is, I think, an example of the way Cold War engineering r&d for national security worked. This report describes aspects of the Sandia National Laboratories.

A strategic surety roadmap for high consequence software systems under the High Integrity Software (HIS) Program at Sandia National Laboratories guides research in identifying methodologies to improve software surety. Selected research tracks within this roadmap are identified and described detailing current technology and outlining advancements to be pursued over the coming decade to reach HIS goals. The tracks discussed herein focus on Correctness by Design, and System Immunology{trademark}. Specific projects are discussed with greater detail given on projects involving Correct Specification via Visualization, Synthesis, & Analysis; Visualization of Abstract Objects; and Correct Implementation of Components.

Computational modeling has been performed to determine optimum operational parameters for a piston-driven molten solder jetting device used to create array interconnects for BGA applications. The device is capable of delivering a 20 x 20 array of 600-800 {mu}m diameter molten 60Sn40Pb solder droplets onto an array of copper pads and primarily consists of an electromechanically driven piston, a heated reservoir, and an orifice plate. computer simulations were performed to determine the relationship between the amplitude and the rate of piston displacement, the onset of fluid ``pinch off``, and the production of satellite droplets. Results show that stable droplets are generated when the volume of the displaced fluid has a spherical diameter that is approximately equal to the orifice diameter.

This document, after giving a summary of Sandia`s mission, describes technology transfer efforts and accomplishments at Sandia. This includes information on their user facilities: the combustion research facility, the national solar thermal test facility, and the electronics quality and reliability center.

NASA-Ames Research Center, in collaboration with Sandia National Laboratories, is developing a Scannerless Terrain Mapper (STM) for autonomous vehicle guidance through the use of virtual reality. The STM sensor is based on an innovative imaging optical radar technology that is being developed by Sandia National Laboratories. The sensor uses active flood-light scene illumination and an image intensified CCD camera receiver to rapidly produce and record very high quality range imagery of observed scenes. The STM is an all solid-state device (containing no moving parts) and offers significant size, performance, reliability, simplicity, and affordability advantages over other types of 3-D sensor technologies, such as scanned laser radar, stereo vision, and structured lighting. The sensor is based on low cost, commercially available hardware, and is very well suited for affordable application to a wide variety of military and commercial uses, including: munition guidance, target recognition, robotic vision, automated inspection, driver enhanced vision, collision avoidance, site security and monitoring, and facility surveying. This paper reviews the sensor technology, discusses NASA`s terrain mapping applications, and presents results from the initial testing of the sensor at NASA`s planetary landscape simulator.