Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. A precise, flexible, and corrosion-resistant underwater rotary spindle was designed and added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometries. A detailed spindle error analysis identifies the major source of error at different frequency. The mathematical model for the material removal of cylindrical wire EDM process is derived. Experiments were conducted to explore the maximum material removal rate for cylindrical and 2D wire EDM of carbide and brass work-materials. Compared to the 2D wire EDM, higher maximum material removal rates may be achieved in the cylindrical wire EDM. This study also investigates the surface integrity and roundness of parts created by the cylindrical wire EDM process. For carbide parts, an arithmetic average surface roughness and roundness as low as 0.68 and 1.7 {micro}m, respectively, can be achieved. Surfaces of the cylindrical EDM parts were examined using Scanning Electron Microscopy (SEM) to identify the craters, sub-surface recast layers and heat-affected zones under various process parameters. This study has demonstrated that the cylindrical wire EDM process parameters can be adjusted to achieve either high …

The key source of uncertainty in assessing actinide mobility is the relative importance of transport by: (1) wind erosion, (2) water erosion, and (3) vertical migration. Each of these three processes depends on several environmental factors and they compete with one another. A scientific assessment of the long-term risks associated with actinides in surface soils depends on better quantifying each of these three modes of mobility. The objective from our EMSP study was to quantify the mobility of soil actinides by wind erosion, water erosion, and vertical migration at three semiarid sites where actinide mobility is a key technical, social and legal issue. This EMSP project was the first to evaluate all three factors at a site. The approach has been to investigate both short- and long-term issues based on field and lab studies and model comparisons. Our results demonstrate the importance of incorporating threshold responses into a modeling framework that accounts for environmental factors and natural disturbances that trigger large changes in actinide mobility. The study measured erosional losses of sediment and fallout cesium (an actinide analogue) from field plots located near WIPP in 1998. The results highlight the large effect of burning as a disturbance on contaminant transport …

This project was initially targeted to the making of coke for blast furnaces by using proprietary technology of Calderon in a phased approach, and Phase I was completed. The project was then re-directed to the making of iron units. U.S. Steel teamed up with Calderon for a joint effort which will last 30 months to produce directly reduced iron with the potential of converting it into molten iron (hot metal) consistent with the Roadmap recommendations of 1998 prepared by the Steel Industry in cooperation with the Department of Energy. The work which is labeled as Phase II will take place at two levels; namely, the bench scale level and the process development unit (PDU) level.

The objective of this project is to demonstrate at pilot scale the use of solid honeycomb catalysts to promote the oxidation of elemental mercury in the flue gas from coal combustion. The project is being funded by the U.S. DOE National Energy Technology Laboratory under Cooperative Agreement DE-FC26-01NT41185. EPRI, Great River Energy (GRE), and City Public Service (CPS) of San Antonio are project co-funders. URS Group is the prime contractor. The mercury catalytic oxidation process under development uses catalyst materials applied to honeycomb substrates to promote the oxidation of elemental mercury in the flue gas from coal-fired power plants that have wet lime or limestone flue gas desulfurization (FGD) systems. Oxidized mercury is removed in the wet FGD absorbers and co-precipitates in a stable form with the byproducts from the FGD system. The co-precipitated mercury does not appear to adversely affect the disposal or reuse properties of the FGD byproduct. The current project will test previously identified, effective catalyst materials at a larger, pilot scale and in a commercial form, so as to provide engineering data for future full-scale designs. The pilot-scale tests will continue for up to 14 months at each of two sites to provide longer-term catalyst life …

The purpose of the Wildlife Management Plan (WMP) is to promote stewardship of the natural resources found at the Brookhaven National Laboratory (BNL), and to integrate their protection with pursuit of the Laboratory's mission.

Three general categories of products from the Estonia Kukersite kerogen oil were defined: pure compounds, broad range concentrates, and sweet refinery feedstock. Product development and market research center on these three categories. Further attempts were made to identify and test chemical approaches for producing lower alkyl resorcinols (what the market requires) from higher alkyl resorcinols. The approaches and process conditions tested have not yet produced satisfactory results. Progress was made to interest industry in the phenolic products producible. A sample of oil from the Galoter retort was received from Estonia and characterization of this sample was initiated. The sample was batch extracted and results of yields and selectivity are reported.

With the advent of fast computer systems, Scientists are now able to generate terabytes of simulation data. Unfortunately, the shear size of these data sets has made efficient exploration of them impossible. To aid scientists in gathering knowledge from their simulation data, we have developed an ad-hoc query infrastructure. Our system, called AQSim (short for Ad-hoc Queries for Simulation) reduces the data storage requirements and access times in two stages. First, it creates and stores mathematical and statistical models of the data. Second, it evaluates queries on the models of the data instead of on the entire data set. In this paper, we present two simple but highly effective statistical modeling techniques for simulation data. Our first modeling technique computes the true mean of systematic partitions of the data. It makes no assumptions about the distribution of the data and uses a variant of the root mean square error to evaluate a model. In our second statistical modeling technique, we use the Andersen-Darling goodness-of-fit method on systematic partitions of the data. This second method evaluates a model by how well it passes the normality test on the data. Both of our statistical models summarize the data so as to answer …

It is long ago recognized that Z-pinches represent very natural medium for x-ray lasers (XRL) due to its favorable geometry and achievable high densities and temperatures. They also are very efficient x-ray sources. One of their variants, the capillary discharges, attracted attention of plasma physics researchers for almost two decades. It has been used for hot dense plasma formation and x-ray lasers[1,2], for transportation of laser beams and XUV radiation generation in x-ray lithography[3,4], for basic Z-pinch research and some others. The combination of efficiency, simplicity and low cost of capillary electrical discharges allowed to scale capillary x-ray lasers to table-top dimensions. In this paper we show the modeling results for next, 3-4 times shorter wavelength x-ray lasers. As an efficient x-ray source of line and continuum radiation it can be used for many practically important application in science and technology. In particular, the capillary discharge can appear as powerful potential candidate for emerging XUV microlithography. We present here the results of numerical modeling of spectra and density of Xe EUV source which involved plasma heating and dynamics, detailed atomic kinetics and radiation transport and material ablation physics.

This is the final report of the accomplishments of the geothermal energy program: information dissemination, public outreach, and technical analysis activities by the project team consisting of the Geo-Heat Center, Geothermal Resources Council, Geothermal Education Office, Geothermal Energy Association, and the Washington State University Energy Program.

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This award supports collaborative research between Kansas State University and Sandia National Laboratories on the topic ''Molecular simulations of complex fluids in confined geometries.'' The objectives of this work are to develop new methodologies for fast and accurate simulations, and to apply simulations to various problems of interest to DOE. The success of this work will address several deficiencies in Sandia's capabilities in the area of molecular simulations. In addition, it provides educational opportunities for students and will enhance the science and technology capabilities at Kansas State through partnership with the national laboratories.

Researchers characterized high-level waste derived from dissolved salt cake from the Savannah River Site (SRS) tank farm and measured the cesium distribution coefficients (DCs) for extraction, scrub, and stripping steps of the caustic-side solvent extraction (CSSX) flowsheet. The measurements used two SRS high-level waste samples derived entirely or in part from salt cake. The chemical compositions of both samples are reported. Dissolved salt cake waste contained less Cs-137 and more dianions than is typical of supernate samples. Extraction, scrub, and strip DCs values for both samples exceeded process requirements and agreed well with model predictions. The results indicate no significant problems processing dissolved salt cake compared to supernate. During the course of testing, researchers observed sorption of cesium on glass sample vials containing strip solutions. The problem was detected in the material balance calculated for each organic/aqueous contact. Methods and recommendations for avoiding this problem are discussed.

A review was conducted of past laboratory-scale test methods and to assess their validity for ranking materials and lubricants for use as piston and liner materials in compression-ignition (CI) and spark-ignition (SI) engines. Most of the previous work was aimed at simulating SI engine environments. This report begins with a discussion of the numerous factors that can affect the validity of an approach to simulating engine conditions in a laboratory. These include not only mechanical, chemical and thermal factors, but also human factors as regards how the vehicle is operated and maintained. The next section provides an annotated review of open literature publications that address the issues of laboratory simulation of engine components. A comparison of these studies indicates a lack of sufficient standardization in procedures to enable a systematic comparison of one publication to another. There were just a few studies that compared several laboratory test methods to engine test results, and these indicated that some test methods correlate, at least qualitatively, better than others. The last section provides a series of recommendations for improving the accuracy and validity of laboratory-scale simulations of engine behavior. It became clear that much of the engine wear damage occurs during start-up when …

This report details results of a study of the solids occurring in process ferrous sulfamate (FS) solutions and the mechanism for their formation and provides recommendations for minimization of these iron-bearing solids.

The D1 and D2 magnets, the first two types of magnets Brookhaven National Laboratory (BNL) is building for the Insertion Regions of Large Hadron Collider (LHC), are being constructed and tested in the BNL magnet test facility. The D1 magnet is cooled using 4.5 K forced flow cooling with three types of bore tube conditions. The D2 magnet is cooled using both liquid helium and forced flow cooling. The liquid cooling scheme, using the shell of the D2 cold mass as the helium vessel and a level gauge in the end volume of the cold mass for liquid control, has been successfully demonstrated. Test results prove that both D1 and D2 meet the performance requirements and that the 4.5 K liquid cooling scheme to be used for D2 and other magnets in the Insertion Regions of LHC is adequate.

This document is the final report on Grant No. DE-FG02-98ER45714, ''Alabama-ORNL Collaboration: Adaptation of Fast Multipole Code for Atomic-scale Micromagnetics.'' It describes the development of a new and efficient code for the calculation of magnetostatic interactions in simulation of magnetic media and disks.

From the experiments performed it is possible to determine a wide range of information about the metallurgy of the astrolabes studied. It was found that different brass alloys were used for components that were cast and those that were mechanically deformed. Chemical composition, forming history, and thickness measurements are all determined non-destructively, illustrating that this technique could be useful for many applications with metal artifact analysis where non-intrusive methods are required.