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Preserving Nuclear Grade Knowledge

Description: When people think of the government they think of the President, or Congress, or the Internal Revenue Service (IRS), but there are thousands of people in government-related jobs doing things most don’t really notice everyday. You can find them everywhere, from the space science folks at NASA, to the Federal Bureau of Investigations (FBI) watching out for the bad guys. There are Rangers, and Social Workers, Nurses and Agricultural Managers. They are people working to keep the many facets of the USA rolling. One very diverse bunch is The Department of Energy (DOE) , a group who is expanding the ways we make and save energy to power our cars, homes, and businesses. Tucked away under the DOE is the National Nuclear Security Administration, the NNSA is an agency that maintains the safety, security, and reliability of the U.S. nuclear weapons stockpile. It works to reduce global danger from weapons of mass destruction. It provides the U.S. Navy with safe nuclear propulsion, and it responds to nuclear and radiological emergencies in the United States and abroad, and it supports efforts in science and technology*. (* DOE/NNSA/KCP website info)
Date: February 5, 2008
Creator: Lange, Bob
Partner: UNT Libraries Government Documents Department

Oil Mist Compliance

Description: This report summarizes activities at the KCP related to evaluating and modifying machine tools in order to be in compliance with Section 23 of DOE 10 CFR 851, Worker Safety and Health Program. Section 851.23 (a) states that “Contractors must comply with the following safety and health standards that are applicable to the hazards in their covered workplace”, and subsection 9 contains the following applicable standard: “American Congress of Governmental Industrial Hygienists (ACGIH), ‘Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices,’ (2005) (incorporated by reference, see §851.27) when the ACGIH Threshold Limit Values are lower (more protective) than permissible exposure limits in 29 CFR 1910.” In the 2005 ACGIH – Threshold Limit Value book a Notice of Change was issued for exposure to mineral oil mist used in metalworking fluids (MWFs). The effects of planning for the new facility and which machine tools would be making the transition to the new facility affected which machine tools were modified.
Date: February 2, 2009
Creator: Lazarus, Lloyd
Partner: UNT Libraries Government Documents Department

New Accessory for Cleaning the Inside of the Machine Tool Cavity

Description: The best way to extend the life of a metalworking fluid (MWF) is to make sure the machine tool and MWF delivery system are properly cleaned at least once per year. The dilemma the MWF manager is faced with is: How does one clean the machine tool and the MWF system on a large machine tool with an enclosure in a timely manner without impacting production schedules? Remember the walls and roof of the machine enclosure are coated with a film of dried contaminated MWF that must also be removed. If not removed, the deposits on these surfaces can recontaminate the fresh charge of MWF. I have found a product that with this revised procedure helps to shorten the machine tool down time involved with machine cleaning. (1) Discuss with your MWF supplier if they have a machine cleaning product that can be used with your current water based MWF during normal machining operations. Most MWF manufacturers have a machine cleaner that can be used at a lower concentration (1-2% vs. 5%) and can be used while still making production parts for a short period of time (usually 24-48 hours). (2) Make sure this machine cleaner is compatible with the work-piece material you are machining into product. Most cleaners are compatible with ferrous alloys. Because of the increased alkalinity of the fluid you might experience staining if you are machining copper or aluminum alloys. (3) Remove the chips from the chips pans and fluid channels. (4) During off shift hours circulate the MWF using a new product marketed by Rego-Fix called a 'Hydroball'. This device has a 5/8 inch diameter straight shank which allows it to be installed in any collet or solid quick change tool holder. It has multiple nozzles so that the user can control the spray pattern ...
Date: April 21, 2009
Creator: Lazarus, Lloyd
Partner: UNT Libraries Government Documents Department

Non-Contact Gaging with Laser Probe

Description: A gage has been constructed using conventional (high end) components for the application of measuring fragile syntactic foam parts in a non-contact mode. Success with this approach has been achieved through a novel method of transferring (mapping) high accuracy local measurements of a coated aluminum master, taken on a Leitz Coordinate Measurement Machine (CMM), to the gage software system. The mapped data is then associated with local voltage readings from two (inner and outer) laser triangulating probes. This couples discreet laser probe offset and linearity characteristics to the measured master geometry. The gage software compares real part measured data against the master data to provide non-contact part inspection that results in a high accuracy and low uncertainty performance. Uncertainty from the part surface becomes the prevailing contributor to the gaging process. The gaging process provides a high speed, hands off measurement with nearly zero impedance.
Date: March 20, 2009
Creator: Clinesmith, Mike
Partner: UNT Libraries Government Documents Department

Lightning Arrestor Connectors Production Readiness

Description: The Lightning Arrestor Connector (LAC), part “M”, presented opportunities to improve the processes used to fabricate LACs. The A## LACs were the first production LACs produced at the KCP, after the product was transferred from Pinnellas. The new LAC relied on the lessons learned from the A## LACs; however, additional improvements were needed to meet the required budget, yield, and schedule requirements. Improvement projects completed since 2001 include Hermetic Connector Sealing Improvement, Contact Assembly molding Improvement, development of a second vendor for LAC shells, general process improvement, tooling improvement, reduction of the LAC production cycle time, and documention of the LAC granule fabrication process. This report summarizes the accomplishments achieved in improving the LAC Production Readiness.
Date: October 20, 2008
Creator: Marten, Steve; Linder, Kim; Emmons, Jim; Gomez, Antonio; Hasam, Dawud & Maurer, Michelle
Partner: UNT Libraries Government Documents Department

Mechanical Devices Readiness FY04.0402.1

Description: This Advanced Design and Production Technologies (ADAPT) project funded production process and tooling improvements to meet and sustain rate production for the program mechanism assemblies. Techniques were developed to allow evaluation and rework of sealed mechanisms that will result in prevention of the scrapping of future mechanisms. Future system mechanisms will likely be smaller with tighter tolerance parts that will require improved inspection equipment and techniques. During the latter phase of this project, the ISL (Intent Stronglink) PRT (Product Realization Team) developed designs and manufacturing processes at Sandia and at multiple KCP (Kansas City Plant) vendors, to produce glass ceramic headers to replace the brazed ceramic headers in the ISL. This achievement will result in significant production costs savings (unit cost and product scrap due to leaking headers).
Date: October 10, 2008
Creator: Bender, Thomas R.
Partner: UNT Libraries Government Documents Department

Mechanical Devices Readiness FY04.0402.3

Description: This project funded production process and tooling improvements to meet and sustain rate production for the W76-1 mechanism assemblies. Techniques were developed to allow evaluation and disposition of sealed stronglinks that resulted in prevention of the scrapping of numerous stronglinks and firesets. Improved processes and tooling allowed D-Test rates to be reduced in favor of E-Test, thus saving millions of dollars over the life of the program. Future system mechanisms will likely be smaller with tighter toleranced parts that will require improved inspection equipment and techniques. During the latter phase of this project, a method of improving inspection was developed that will have benefits for existing and future system mechanical assemblies.
Date: October 21, 2008
Creator: Fitzgerald, John M.
Partner: UNT Libraries Government Documents Department

The Study and Implementation of Electrically Small Printed Antennas for an Integrated Transceiver Design

Description: This work focuses on the design and evaluation of the inverted-F, meandering-monopole, and loop antenna geometries. These printed antennas are studied with the goal of identifying which is suitable for use in a miniaturized transceiver design and which has the ability to provide superior performance using minimal Printed Circuit Board (PCB) space. As a result, the main objective is to characterize tradeoffs and identify which antenna provides the best compromise among volume, bandwidth and efficiency. For experimentation purposes, three types of meandering-monopole antenna are examined resulting in five total antennas for the study. The performance of each antenna under study is evaluated based upon return loss, operational bandwidth, and radiation pattern characteristics. For our purposes, return loss is measured using the S11-port reflection coefficient which helps to characterize how well the small antenna is able to be efficiently fed. Operational bandwidth is measured as the frequency range over which the antenna maintains 2:1 Voltage Standing Wave Ratio (VSWR) or equivalently has 10-dB return loss. Ansoft High Frequency Structure Simulator (HFSS) is used to simulate expected resonant frequency, bandwidth, VSWR, and radiation pattern characteristics. Ansoft HFSS simulation is used to provide a good starting point for antenna design before actual prototype are built using an LPKF automated router. Simulated results are compared with actual measurements to highlight any differences and help demonstrate the effects of antenna miniaturization. Radiation characteristics are measured illustrating how each antenna is affected by the influence of a non-ideal ground plane. The antenna with outstanding performance is further evaluated to determine its maximum range of communication. Each designs range performance is evaluated using a pair of transceivers to demonstrate round-trip communication. This research is intended to provide a knowledge base which will help decrease the number of design iterations needed for future implementation of products requiring integration ...
Date: April 15, 2009
Creator: Speer, Pete
Partner: UNT Libraries Government Documents Department

Virtual Optical Comparator

Description: The Virtual Optical Comparator, VOC, was conceived as a result of the limitations of conventional optical comparators and vision systems. Piece part designs for mechanisms have started to include precision features on the face of parts that must be viewed using a reflected image rather than a profile shadow. The VOC concept uses a computer generated overlay and a digital camera to measure features on a video screen. The advantage of this system is superior edge detection compared to traditional systems. No vinyl charts are procured or inspected. The part size and expensive fixtures are no longer a concern because of the range of the X-Y table of the Virtual Optical Comparator. Product redesigns require only changes to the CAD image overlays; new vinyl charts are not required. The inspection process is more ergonomic by allowing the operator to view the part sitting at a desk rather than standing over a 30 inch screen. The procurement cost for the VOC will be less than a traditional comparator with a much smaller footprint with less maintenance and energy requirements.
Date: October 20, 2008
Creator: Thompson, Greg
Partner: UNT Libraries Government Documents Department

A Voltage Controlled Oscillator for a Phase-Locked Loop Frequency Synthesizer in a Silicon-on-Sapphire Process

Description: Engineers from a government-owned engineering and manufacturing facility were contracted by government-owned research laboratory to design and build an S-band telemetry transmitter using Radio Frequency Integrated Circuit (RFIC) technology packaged in a Low-Temperature Co-fired Ceramic (LTCC) Multi-Chip Module. The integrated circuit technology chosen for the Phase-Locked Loop Frequency Synthesizer portion of the telemetry transmitter was a 0.25 um CMOS process that utilizes a sapphire substrate and is fabricated by Peregrine Semiconductor corporation. This thesis work details the design of the Voltage Controlled Oscillator (VCO) portion of the PLL frequency synthesizer and constitutes an fully integrated VCO core circuit and a high-isolation buffer amplifier. The high-isolation buffer amplifier was designed to provide 16 dB of gain for 2200-3495 MHz as well as 60 dB of isolation for the oscillator core to provide immunity to frequency pulling due to RF load mismatch. Actual measurements of the amplifier gain and isolation showed the gain was approximately 5 dB lower than the simulated gain when all bond-wire and test substrate parasitics were taken into account. The isolation measurements were shown to be 28 dB at the high end of the frequency band but the measurement was more than likely compromised due to the aforementioned bond-wire and test substrate parasitics. The S-band oscillator discussed in this work was designed to operate over a frequency range of 2200 to 2300 MHz with a minimum output power of 0 dBm with a phase-noise of -92 dBc/Hz at a 100 kHz offset from the carrier. The tuning range was measured to be from 2215 MHz to 2330 MHz with a minimum output power of -7 dBm over the measured frequency range. A phase-noise of -90 dBc was measured at a 100 kHz offset from the carrier.
Date: May 21, 2009
Creator: Garrison, Sean
Partner: UNT Libraries Government Documents Department

Rapid Response Small Machining NNR Project 703025

Description: This project was an effort to develop a machining area for small sized parts that is capable of delivering product with a quick response time. This entailed focusing efforts on leaning out specific work cells that would result in overall improvement to the entire machining area. This effort involved securing the most efficient available technologies for these areas. In the end, this incorporated preparing the small machining area for transformation to a new facility.
Date: December 5, 2008
Creator: Kanies, Tim
Partner: UNT Libraries Government Documents Department

Response Predicting LTCC Firing Shrinkage: A Response Surface Analysis Study

Description: The Low Temperature Cofired Ceramic (LTCC) technology is used in a variety of applications including military/space electronics, wireless communication, MEMS, medical and automotive electronics. The use of LTCC is growing due to the low cost of investment, short development time, good electrical and mechanical properties, high reliability, and flexibility in design integration (3 dimensional (3D) microstructures with cavities are possible)). The dimensional accuracy of the resulting x/y shrinkage of LTCC substrates is responsible for component assembly problems with the tolerance effect that increases in relation to the substrate size. Response Surface Analysis was used to predict product shrinkage based on specific process inputs (metal loading, layer count, lamination pressure, and tape thickness) with the ultimate goal to optimize manufacturing outputs (NC files, stencils, and screens) in achieving the final product design the first time. Three (3) regression models were developed for the DuPont 951 tape system with DuPont 5734 gold metallization based on green tape thickness.
Date: February 25, 2009
Creator: Girardi, Michael; Barner, Gregg; Lopez, Cristie; Duncan, Brent & Zawicki, Larry
Partner: UNT Libraries Government Documents Department

Selection and Implementation of a Replacement Cutting Tool Selection Application

Description: A new commercial cutting tool software package replaced an internally created legacy system. This report describes the issues that surfaced during the migration and installation of the commercial package and the solutions employed. The primary issues discussed are restructuring the data between two drastically different database schemas and the creation of individual component graphics.
Date: October 6, 2008
Creator: Rice, Gordon
Partner: UNT Libraries Government Documents Department

Spin-forming Project Report

Description: In a second development order, spin-forming equipment was again evaluated using the test shape, a hemispherical shell. In this second development order, pure vanadium and alloy titanium (Ti-6Al-4V) were spin-formed, as well as additional copper and 21-6-9 stainless. In the first development order the following materials had been spin-formed: copper (alloy C11000 ETP), 6061 aluminum, 304L stainless steel, 21-6-9 stainless steel, and tantalum-2.5% tungsten. Significant challenges included properly adjusting the rotations-per-minute (RPM), cracking at un-beveled edges and laser marks, redressing of notches, surface cracking, non-uniform temperature evolution in the titanium, and cracking of the tailstock. Lessons learned were that 300 RPM worked better than 600 RPM for most materials (at the feed rate of 800 mm/min); beveling the edges to lower the stress reduces edge cracking; notches, laser marks, or edge defects in the preform doom the process to cracking and failure; coolant is required for vanadium spin-forming; increasing the number of passes to nine or more eliminates surface cracking for vanadium; titanium develops a hot zone in front of the rollers; and the tailstock should be redesigned to eliminate the cylindrical stress concentrator in the center.
Date: March 20, 2009
Creator: Switzner, Nathan & Henry, Dick
Partner: UNT Libraries Government Documents Department

CMM Technology

Description: This project addressed coordinate measuring machine (CMM) technology and model-based engineering. CMM data analysis and delivery were enhanced through the addition of several machine types to the inspection summary program. CMM hardware and software improvements were made with the purchases of calibration and setup equipment and new model-based software for the creation of inspection programs. Kansas City Plant (KCP) personnel contributed to and influenced the development of dimensional metrology standards. Model-based engineering capabilities were expanded through the development of software for the tolerance analysis of piece parts and for the creation of model-based CMM inspection programs and inspection plans and through the purchase of off-the-shelf software for the tolerance analysis of mechanical assemblies. An obsolete database application used to track jobs in Precision Measurement was replaced by a web-based application with improved query and reporting capabilities. A potential project to address the transformation of the dimensional metrology enterprise at the Kansas City Plant was identified.
Date: October 20, 2008
Creator: Ward, Robert C.
Partner: UNT Libraries Government Documents Department

Conveyorized Photoresist Stripping Replacement for Flex Circuit Fabrication

Description: A replacement conveyorized photoresist stripping system was characterized to replace the ASI photoresist stripping system. This system uses the qualified ADF-25c chemistry for the fabrication of flex circuits, while the ASI uses the qualified potassium hydroxide chemistry. The stripping process removes photoresist, which is used to protect the copper traces being formed during the etch process.
Date: February 24, 2009
Creator: Donahue, Megan
Partner: UNT Libraries Government Documents Department

3-D Microprobe Metrology

Description: This report documents the results of a project undertaken to develop an ultra-high-accuracy measurement capability, which is necessary to address a rising trend toward miniaturized mechanical products exhibiting dramatically reduced product tolerances. A significant improvement in measurement capability is therefore required to insure that a 4:1 ratio can be maintained between product tolerances and measurement uncertainty.
Date: October 14, 2008
Creator: Swallow, Kevin
Partner: UNT Libraries Government Documents Department

Agile Machining and Inspection Non-Nuclear Report (NNR) Project

Description: This report is a high level summary of the eight major projects funded by the Agile Machining and Inspection Non-Nuclear Readiness (NNR) project (FY06.0422.3.04.R1). The largest project of the group is the Rapid Response project in which the six major sub categories are summarized. This project focused on the operations of the machining departments that will comprise Special Applications Machining (SAM) in the Kansas City Responsive Infrastructure Manufacturing & Sourcing (KCRIMS) project. This project was aimed at upgrading older machine tools, developing new inspection tools, eliminating Classified Removable Electronic Media (CREM) in the handling of classified Numerical Control (NC) programs by installing the CRONOS network, and developing methods to automatically load Coordinated-Measuring Machine (CMM) inspection data into bomb books and product score cards. Finally, the project personnel leaned perations of some of the machine tool cells, and now have the model to continue this activity.
Date: February 19, 2009
Creator: Lazarus, Lloyd
Partner: UNT Libraries Government Documents Department

ALT-GTS-Stem Fabrication

Description: In 2007, a study investigated options to manufacture stems utilizing methods that would replace crush form grinding while maintaining or improving quality at a comparative cost. Crush form grinding is a special process used at the Kansas City Plant to finish stem sections of reservoir products. However, crush form grinding is a complex process with many variables affecting the final product. This study identified two potential methods that can be applied to stems. Profile grinding was investigated in 2007. This project continued in 2008 proving that single point turning on a multi-turret is an option with additional benefits. It is an economical way to meet floor space limitations for our KCRIMS mission.
Date: September 25, 2008
Creator: Nguyen, Thuan
Partner: UNT Libraries Government Documents Department

Atmospheric Plasma Deposition of Diamond-like Carbon Coatings

Description: There is great demand for thin functional coatings in the semiconductor, optics, electronics, medical, automotive and aerospace industries [1-13]. As fabricated components become smaller and more complex, the properties of the materials’ surface take on greater importance. Thin coatings play a key role in tailoring surfaces to give them the desired hardness, wear resistance, chemical inertness, and electrical characteristics. Diamond-like carbon (DLC) coatings possess an array of desirable properties, including outstanding abrasion and wear resistance, chemical inertness, hardness, a low coefficient of friction and exceptionally high dielectric strength [14-22]. Diamond-like carbon is considered to be an amorphous material, containing a mixture of sp2 and sp3 bonded carbon. Based on the percentage of sp3 carbon and the hydrogen content, four different types of DLC coatings have been identified: tetrahedral carbon (ta-C), hydrogenated amorphous carbon (a-C:H) hard, a-C:H soft, and hydrogenated tetrahedral carbon (ta-C:H) [20,24,25]. Possessing the highest hardness of 80 GPa, ta-C possesses an sp3 carbon content of 80 to 88u%, and no appreciable hydrogen content whereas a-C:H soft possesses a hardness of less than 10 GPa, contains an sp3 carbon content of 60% and a hydrogen content between 30 to 50%. Methods used to deposit DLC coatings include ion beam deposition, cathodic arc spray, pulsed laser ablation, argon ion sputtering, and plasma-enhanced chemical vapor deposition [73-83]. Researchers contend that several advantages exist when depositing DLC coatings in a low-pressure environment. For example, ion beam processes are widely utilized since the ion bombardment is thought to promote denser sp3-bonded carbon networks. Other processes, such as sputtering, are better suited for coating large parts [29,30,44]. However, the deposition of DLC in a vacuum system has several disadvantages, including high equipment cost and restrictions on the size and shape of material that may be treated. The deposition of DLC at atmospheric pressure has ...
Date: January 23, 2008
Creator: Ladwig, Angela
Partner: UNT Libraries Government Documents Department

Design of Experiments to Determine Causes of Flex Cable Solder Wicking, Discoloration and Hole Location Defects

Description: Design of Experiments (DoE) were developed and performed in an effort to discover and resolve the causes of three different manufacturing issues; large panel voids after Hot Air Solder Leveling (HASL), cable hole locations out of tolerance after lamination and delamination/solder wicking around flat flex cable circuit lands after HASL. Results from a first DoE indicated large panel voids could be eliminated by removing the pre-HASL cleaning. It also revealed eliminating the pre-HASL bake would not be detrimental when using a hard press pad lamination stackup. A second DoE indicated a reduction in hard press pad stackup lamination pressure reduced panel stretch in the y axis approximately 70%. A third DoE illustrated increasing the pre-HASL bake temperature could reduce delamination/solder wicking when using a soft press pad lamination stackup.
Date: April 22, 2009
Creator: Wolfe, Larry
Partner: UNT Libraries Government Documents Department

Developing the Manufacturing Process for Hylene MP Curing Agent

Description: This report details efforts to scale-up and re-establish the manufacturing process for the curing agent known as Hylene MP. First, small scale reactions were completed with varying conditions to determine key drivers for yielding high quality product. Once the optimum conditions were determined on the small scale, the scaled-up process conditions were determined. New equipment was incorporated into the manufacturing process to create a closed production system and improve chemical exposure controls and improve worker safety. A safe, efficient manufacturing process was developed to manufacture high quality Hylene MP in large quantities.
Date: February 16, 2009
Creator: Eastwood, Eric
Partner: UNT Libraries Government Documents Department

Development and Implementation of a Program Management Maturity Model

Description: In 2006, Honeywell Federal Manufacturing & Technologies (FM&T) announced an updatedvision statement for the organization. The vision is “To be the most admired team within the NNSA [National Nuclear Security Administration] for our relentless drive to convert ideas into the highest quality products and services for National Security by applying the right technology, outstanding program management and best commercial practices.” The challenge to provide outstanding program management was taken up by the Program Management division and the Program Integration Office (PIO) of the company. This article describes how Honeywell developed and deployed a program management maturity model to drive toward excellence.
Date: December 15, 2008
Creator: Hartwig, Laura & Smith, Matt
Partner: UNT Libraries Government Documents Department