This report summarizes the generating unit capacity changes projected for 1979-1988 by the Regional Electric Reliability Councils in their April 1, 1979, Coordinated Long-Range Planning Reports to the Department of Energy.

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A light reflection technique suitable for development into an automated surface quality certification system was investigated to determine if reflected light intensity distributions could be corre]ated with surface defect depths. Reflected laser light intensity distributions from pit and scratch defects on highly reflective spheres were studied with a commercial multi-element photodetector. It was found that the intensity distributions --Goll'lf be correlated with depths of pits and scratches in a size range of concern on highly reflective' spheres.

Bendix now makes four component parts for one precision mechanical assembly from investment castings rather than from wrought-stock machined and welded assemblies--a conversion based directly on the cost saving potential. With proper evaluation of metal components for casting suitability and usage, manufacturers may realize cost saving far beyond their expectations.

The chemistry of the various types of reactions possible between a carboxyl-terminated butadiene/acrylonitrile (CBTN) liquid copolymer and a diglycidyl ether of bisphenol A (DGEBA) type epoxy resin to prepare a CTBN/DGEBA adduct is discussed. Both a dilution and a non-dilution synthesis techniqu are described. Several properties of the CTBN precursor and the modified epoxy resin were determined and are presented.

A study was made of resins based on methyl-alpha-(D)-glucoside. Foams prepared using this resin and a prepolymer based on polymethylene polyphenyl isocyanate had excellent high temperature strength when tested At 400°F (301.1°C). Best results were obtained with methyl glucoside purchased as a 65-percent water solution containing 30 percent beta-methyl-glucoside.

A radiographic image analyzer and a modified shielded-enclosure leak-detection system were successful in determining the cable shield coverage and the freedom from leakage necessary to prevent interference caused by electromagnetic radiation pickup on interconnecting cables. Other systems are being considered, and further evaluation and refinement are necessary to provide reliable methods for in-process manufacturing tests and product analysis.

The first two phases of a program designed to determine the effects of boric acid on the cure of Y-3602 silicone gum were conducted to evaluate extraction solvents and extraction time. The standard production formulation of B10-filled Y-3602 silicone gum was used in these evaluations. Results showed that the best solvent for reproducibility and high amine content was chloroform. The second phase indicated that extraction was essentially complete at the end of 4 hours.

Moisture-sensitive systems to measure and indicate the maximum level of humidity exposure are discussed. A chemical indicator utilizing deliquescent salts and water-soluble dyes provides an irreversible color change at discrete levels of relative humidity. To provide indication of the time at which the exposure occurs, a circuit employing a resistive-type sensor was developed. A small, commercially available sensor is used in a portable probe to detect humidity leaks into controlled areas.

Taking two resistance readings, at room temperature and at -196°C when the substrate is submerged in liquid nitrogen provides a convenient means of measuring the TCR of tantalum-nitride films. The liquid nitrogen provides a large, controlled temperature differential that can be used conveniently in the production environment. A digital-readout tester with only a simple nulling adjustment makes it possible to read the TCR of the film directly on the DVM indicator. This method provides the prompt TCR information feedback necessary to control the tantalum-nitride sputtering process and results in substantial time and materials savings.

This work resulted in development of the necessary techniques to automatically measure radar receiver and system sensitivity. Both measurement speed and repeatability are improved over that possible by manual methods. Combined logic and analog techniques were used to derive a system suitable for both in-process and final-assembly tests on radar systems and rf subassemblies.

A method has been developed for suppressing parasitic oscillation of transistors operating under test conditions through the use of ferrite cores and capacitors. The Hewlett-Packard Model 8554L spectrum analyzer is recommended for detecting unknown rf noise.

Mass anodization of tantalum-nitride films with sheet resistivities not exceeding 200 ohms per square to meet ±10-percent tolerance requirements on resistors above 100 ohms has been shown feasible. The anodization system that was developed for this study is capable of producing yields of approximately 80 percent under those conditiohs. Although anodization trimming on films with sheet resistivities as high as 600 ohms per square is now feasible, further work is necessary to successfully anodize films above 600 ohms per square and resistors below 100 ohms.

The mechanical, electrical, and thermal properties of a general purpose epoxy potting compound, filled with either glass microspheres or aluminum oxide and catalyzed with either diethanolamine or Epon Z are discussed. Twelve formulation-cure cycle combinations were chosen for evaluation. The temperature properties from -65 to 400°F (-54 to 204°C) of four of the combinations are given. Modulus versus temperature polynomials were calculated for the diethanolamine catalyzed material.

The feasibility of using EN-7 as a substitute for Adiprene L100 curing agent for analyzer encapsulation was investigated. Since many analyzer assemblies cannot tolerate the usual EN-7 cure temperatures, this investigation was limited to a maximum cure temperatureof 710°C. The results of these tests indicate that a 20-hour cure at 490°C is adequate to provide sufficient hardness if followed by additional room-temperature cure.

A forming station has been designed and fabricated. The forming stations allow automatic control of the pressure, temperature, vacuum, and cooling cycles required for pressure/vacuum dies used to form or bond aluminum-Mylar laminate, Mylar films, and polycarbonate sheets.

Studies were conducted on three TDI polyurethane foam materials to improve production yields of molded-to-size parts. The effects of changes in cell. stabilizers, emulsifiers, catalysts, and the blowing agent were investigated. To evaluate formulation modifications, tests were performed to determine compressive strength, foam reactivity, and free-rise density. Changes in the visual appearance were also documented. Silicone surfactants were found to be superior to organic emulsifiers. In addition, an increase in water content produced parts rated superior to those produced by using the standard formulation for one material, Rigifoam 6003-2.5.

The mechanical, physical, and thermal properties of a glass microballoon-filled polybenzimidazole resin have been measured for test specimens molded by three manufacturing processes. The material, Imidite X386, has been shown to be a high strength, thermally stable structural foam.