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NASA NTRS2003

Process-Based Cost Estimation for Ramjet/Scramjet Engines

Process-based cost estimation plays a key role in effecting cultural change that integrates distributed science, technology and engineering teams to rapidly create innovative and affordable products. Working together, NASA Glenn Research Center and Boeing Canoga Park have developed a methodology of process-based cost estimation bridging the methodologies of high-level parametric models and detailed bottoms-up estimation. The NASA GRC/Boeing CP process-based cost model provides a probabilistic structure of layered cost drivers. High-level inputs characterize mission requirements, system performance, and relevant economic factors. Design alternatives are extracted from a standard, product-specific work breakdown structure to pre-load lower-level cost driver inputs and generate the cost-risk analysis. As product design progresses and matures the lower level more detailed cost drivers can be re-accessed and the projected variation of input values narrowed, thereby generating a progressively more accurate estimate of cost-risk. Incorporated into the process-based cost model are techniques for decision analysis, specifically, the analytic hierarchy process (AHP) and functional utility analysis. Design alternatives may then be evaluated not just on cost-risk, but also user defined performance and schedule criteria. This implementation of full-trade study support contributes significantly to the realization of the integrated development environment. The process-based cost estimation model generates development and manufacturing cost estimates. The development team plans to expand the manufacturing process base from approximately 80 manufacturing processes to over 250 processes. Operation and support cost modeling is also envisioned. Process-based estimation considers the materials, resources, and processes in establishing cost-risk and rather depending on weight as an input, actually estimates weight along with cost and schedule.

Singh, Brijendra↗

NASA NTRS2004

Processing Spacecraft Data Without Confusion

Producing multiple versions of the same data product for the same time frame with the same remotely sensed inputs can be a recipe for disaster. Yet, amidst the commotion of satellite launch and early operations (LEO), such data processing is needed. After LEO, the situation gets worse. Processing newly arriving data ("forward processing") is augmented with reprocessing and algorithm development, comparison, evaluation, and testing -- often happening all at the same time. The problem can be analyzed in three main parts -- maintaining multiple versions of algorithms and data so that end-product users are not overwhelmed,allocating computer resources efficiently, and simplifying production operations so that va st amounts of data can be processed with minimal staff and fewer errors. OMIDAPS provides a framework for execution of algorithms that transform lower level data acquired by OMI on NASA's Aura satellite into higher level science data products. In contrast to traditional science data processing systems, we address all parts of the problem with an innovative approach allowing multiple data processing to run within a single physical system. The data products, imports, exports, and execution planning are all segregated into distinct "ArchiveSets." This paper describes reasons for multiple concurrent productions on a typical satellite data processing project using OMI as an example. It describes the virtual data processing system concept and its advantages over separate physical processing strings. It explores the specific implementation of the virtual systems within OMIDAPS and discusses some of the implications of our approach and describes how virtual processing is used to accomplish the overall mission of OMI data processing.

Tilmes, Curt↗

NASA NTRS2011

Modeling Constellation Virtual Missions Using the Vdot(Trademark) Process Management Tool

The authors have identified a software tool suite that will support NASA's Virtual Mission (VM) effort. This is accomplished by transforming a spreadsheet database of mission events, task inputs and outputs, timelines, and organizations into process visualization tools and a Vdot process management model that includes embedded analysis software as well as requirements and information related to data manipulation and transfer. This paper describes the progress to date, and the application of the Virtual Mission to not only Constellation but to other architectures, and the pertinence to other aerospace applications. Vdot s intuitive visual interface brings VMs to life by turning static, paper-based processes into active, electronic processes that can be deployed, executed, managed, verified, and continuously improved. A VM can be executed using a computer-based, human-in-the-loop, real-time format, under the direction and control of the NASA VM Manager. Engineers in the various disciplines will not have to be Vdot-proficient but rather can fill out on-line, Excel-type databases with the mission information discussed above. The author s tool suite converts this database into several process visualization tools for review and into Microsoft Project, which can be imported directly into Vdot. Many tools can be embedded directly into Vdot, and when the necessary data/information is received from a preceding task, the analysis can be initiated automatically. Other NASA analysis tools are too complex for this process but Vdot automatically notifies the tool user that the data has been received and analysis can begin. The VM can be simulated from end-to-end using the author s tool suite. The planned approach for the Vdot-based process simulation is to generate the process model from a database; other advantages of this semi-automated approach are the participants can be geographically remote and after refining the process models via the human-in-the-loop simulation, the system can evolve into a process management server for the actual process.

Hardy, Roger↗

NASA NTRS2005

Semiautomated, Reproducible Batch Processing of Soy

A computer-controlled apparatus processes batches of soybeans into one or more of a variety of food products, under conditions that can be chosen by the user and reproduced from batch to batch. Examples of products include soy milk, tofu, okara (an insoluble protein and fiber byproduct of soy milk), and whey. Most processing steps take place without intervention by the user. This apparatus was developed for use in research on processing of soy. It is also a prototype of other soy-processing apparatuses for research, industrial, and home use. Prior soy-processing equipment includes household devices that automatically produce soy milk but do not automatically produce tofu. The designs of prior soy-processing equipment require users to manually transfer intermediate solid soy products and to press them manually and, hence, under conditions that are not consistent from batch to batch. Prior designs do not afford choices of processing conditions: Users cannot use previously developed soy-processing equipment to investigate the effects of variations of techniques used to produce soy milk (e.g., cold grinding, hot grinding, and pre-cook blanching) and of such process parameters as cooking times and temperatures, grinding times, soaking times and temperatures, rinsing conditions, and sizes of particles generated by grinding. In contrast, the present apparatus is amenable to such investigations. The apparatus (see figure) includes a processing tank and a jacketed holding or coagulation tank. The processing tank can be capped by either of two different heads and can contain either of two different insertable mesh baskets. The first head includes a grinding blade and heating elements. The second head includes an automated press piston. One mesh basket, designated the okara basket, has oblong holes with a size equivalent to about 40 mesh [40 openings per inch (.16 openings per centimeter)]. The second mesh basket, designated the tofu basket, has holes of 70 mesh [70 openings per inch (.28 openings per centimeter)] and is used in conjunction with the press-piston head. Supporting equipment includes a soy-milk heat exchanger for maintaining selected coagulation temperatures, a filter system for separating okara from other particulate matter and from soy milk, two pumps, and various thermocouples, flowmeters, level indicators, pressure sensors, valves, tubes, and sample ports

Thoerne, Mary↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Paul Gradl↗

NASA NTRS2023

Leveraging Automated Fiber Placement Computer Aided Process Planning Framework for Defect Validation and Dynamic Layup Strategies

Process planning represents an essential stage of the Automated Fiber Placement (AFP) workflow. It develops useful and efficient machine processes based upon the working material, composite design, and manufacturing resources. The current state of process planning requires a high degree of interaction from the process planner and could greatly benefit from increased automation. Therefore, a list of key steps and functions are created to identify the more difficult and time-consuming phases of process planning. Additionally, a set of metrics must exist by which to evaluate the effectiveness of the manufactured laminate from the machine code created during the Process Planning stage. Layup strategies, in addition to dog ears, stagger shifts, steering constraints, and starting points, represented the group of functions labeled as process optimization and ranked the highest in terms of priority for automation. The laminates resulting from the selected parameters are evaluated through the occurrences of principal defect metrics such as fiber gaps, overlaps, angle deviation and steering violations. This document presents an automated software solution to the layup strategy and starting point selection phase of process planning. A series of ply scenarios are generated with variations of these ply parameters and evaluated according to a set of metrics entered by the Process Planner. These metrics are generated through use of the Analytical Hierarchy Process (AHP), where relative importance between each of the fiber features are defined. The ply scenarios are selected which reduce the overall fiber feature scores based on the defects the Process Planner wishes to minimize.

HiCAM↗

NASA NTRS2024

Moon to Mars (M2M) Cross Program Utilization Payload Safety Process

It is the goal of Moon to Mars (M2M) to establish a single consolidated set of safety requirements and a safety review process for utilization payloads that will cross program vehicle hatches or operate externally on multiple program vehicles during transport or operation that satisfies Exploration Ground Systems (EGS), Orion, EVA, and Human Surface Mobility Program (EHP), Gateway (GW), and Human Landing System (HLS) programs. This document defines the Cross Program Utilization Payload (xPUP) safety review process for mission effectivity of Artemis III and beyond. This review process will help ensure protection of the overall Moon to Mars integrated system from potential hazards created by cross program payloads that either cross a program vehicle hatch or can interface with more than one M2M lunar exploration program vehicle. The process will identify payload hazards and controls that will protect ground personnel, flight crew, the integrated vehicle, ground equipment, or facilities. This process is also applicable to samples that cross hatches between vehicles including for return to Earth. The xPUP safety review process will be led by one of the M2M programs' integration safety panels, chosen on a per-payload basis. After the lead integration safety panel is determined, the common safety process is established, based on pre-determined criteria, which includes ad-hoc members from other stakeholder programs. Stakeholder programs are those that interface with the utilization payload in any way (e.g., operating on a lunar exploration vehicle or crossing program vehicle hatches). The xPUP will execute this safety review process for flight and ground utilization payload hardware design, its ground support equipment, and landing and recovery in accordance with the applicable safety requirements as specified in M2M-30043: Moon to Mars Cross Program Utilization Payload Safety Requirements. The xPUP safety process will follow the lead integration safety panel’s safety process requirements. Formal agreements will be communicated with the payload developer using the payload integration processes documented in M2M-30037, Artemis Payload Integration Implementation Plan.

payloads↗

DOE OSTI2018

Power management across heterogeneous processing units

A method includes controlling active frequency states of a plurality of heterogeneous processing units based on frequency sensitivity metrics indicating performance coupling between different types of processing units in the plurality of heterogeneous processing units. A processor includes a plurality of heterogeneous processing units and a performance controller to control active frequency states of the plurality of heterogeneous processing units based on frequency sensitivity metrics indicating performance coupling between different types of processing units in the plurality of heterogeneous processing units. The active frequency state of a first type of processing unit in the plurality of heterogeneous processing units is controlled based on a first activity metric associated with a first type of processing unit and a second activity metric associated with a second type of processing unit.

Paul, Indrani↗

DOE OSTI2015

Radiometric characterization process for locating radioactivity hold-up and measuring non-uniformly distributed sources - 15342

A novel approach to facility radiometric characterization for non-uniformly distributed radiation sources has been developed by ANTECH and is currently being employed at the Argonne National Laboratory. It is being applied to the measurement of a wide range of objects and the interiors and contents of laboratories and buildings. The integrated non destructive assay measurement process involves the use of a scanning spectroscopic gamma ray camera as well as high purity Germanium detectors with different collimators and hence differing detector fields of view to measure and quantify non-uniformly distributed sources of radioactivity in laboratory equipment, glove boxes, storage tanks, pipework and general laboratory objects and process components. The purpose of the radiometric characterization is to quantify radiation sources and radioactive contamination levels in facilities containing nuclear material and to ensure compliance with facility characterization requirements and for decontamination and decommissioning planning and execution. The integrated measurement process also involves automated data capture and processing software and a database with which both measurement instrument operators and subject matter expert analysts can interact. An appropriate measuring instrument (gamma camera, scintillation detector, high purity Germanium detector system, neutron detector or alpha-beta counter) records the measurement data and the measurement site is recorded in a photograph. All of the data relevant to the measurement (or set of measurements for a particular object) are recorded in the database including measured gamma ray spectra, equipment description and relevant calibration, measurement site photograph and measurement descriptive data. Once data analysis protocols are established for specific geometries and measurement situations they can be applied to the measured data in a partially automated manner, reducing analysis and transcription errors. In addition to measurements and data analysis the process also utilises radiometric modelling computer codes including MicroShield and Monte Carlo Neutrons Photons in order to perform model calculations where appropriate. In a typical measurement, the ANTECH RadSearch spectroscopic gamma camera is utilized to find areas of concentrated activity so that these areas can be measured and calculated separately from areas with diffuse contamination. The use of the gamma camera in scanning mode helps to ensure that the assay does not overestimate the detected radiation source, which is a frequent consequence of using standard far field geometry and attenuation analysis codes that assume uniformity of both density and radioactive source distribution. Once the hot spots are identified, high purity Germanium detector measurements are made using various collimators with wide or narrow fields of view as required. These measurements are then processed through a semi-automatic calculation process assuming an appropriate source configuration as identified by RadSearch. These source configurations include point sources, line sources or surface sources. The Generalized Geometry Hold-up algorithms are employed to determine an estimate of the activity of the various sources that are identified in a measurement. The ANTECH integrated measurement process provides an automated calculation procedure where the analyst can select the source type, geometry and appropriate input data, and then the software calculates the activity by radionuclide for all sources identified in the measurement. The measurement and analysis process is controlled under the ANTECH ISO9001: 2008 Quality Assurance System and managed by a site specific Quality Assurance Plan. Both Argonne National Laboratory and Department of Energy technical reviewers have vetted the Integrated Measurement and Analysis Process. The application of the measurement and analysis process is described and measurement examples are provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Pseudo-dynamic Aspen Plus{sup R} Model of the Defense Waste Processing Facility - 18475

The Defense Waste Processing Facility (DWPF) at the Savannah River Site converts legacy high-level waste from the Cold War into borosilicate glass for permanent disposal in a geological repository. The waste sludge is chemically adjusted by the addition of acid, mixed with frit, and concentrated in the DWPF Chemical Process Cell (CPC) to ensure that the final glass has the desired properties. The resulting mixture is fed into the melter where the waste is melted and poured into stainless steel storage canisters. We present an Aspen Plus{sup R} model of the DWPF CPC, which is being developed to aid chemical processing decisions pertaining to the current flowsheet and to aid decisions regarding optimizing future processing. Given a waste feed composition with acid and frit additions, the model will predict the sludge and off-gas compositions throughout the processing, as well as the final melter feed composition. This allows different processing scenarios to be investigated easily, reducing the reliance on experimental testing, and hence saving time and money. The model has multiple potential applications, including calculating the acid and frit additions required to give acceptable glass properties, off-gas permitting, tracking mercury steam-stripped from the waste in the off-gas system, tracking flammable gases in the offgas system, investigating the effect of reducing air purges in the condensers, and general process optimization. The waste is processed in the CPC in batches, requiring dynamic simulation to track the time-dependent operations. Accurate modeling of the processing also requires calculations of phase and electrolyte chemical equilibria and parallel rate-dependent reactions. Due to existing technical limitations with dynamic simulation of the complex chemical system, we have adopted a pseudo-dynamic approach in which time intervals are treated as consecutive steady-state operations in Aspen Plus{sup R}. Thus, the model consists of ∼100 replicas of the processing vessel and its off-gas system, with the sludge output by one replica (representing one time interval) becoming the feed to the next (representing the next time interval). By examining the results from these replicas in sequence, one can see the time evolution of the model. This general approach can be used wherever simultaneous calculation of phase and electrolyte chemical equilibria in a dynamically evolving system is needed. In addition to describing the general structure and chemistry of the model, we present results from tests of the model against experimental data. These data are from laboratory-scale process simulations of the CPC with a nonradioactive waste sludge simulant. These tests include the model's predictions of the offgas composition, the sludge pH, and the final sludge composition. We will also discuss planned future developments of the model. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Radiopaque particle processing additive

A radiopaque processing medium comprising a plurality of radiopaque particles and a non-radiopaque processing medium. The plurality of radiopaque particles is added to the non-radiopaque processing medium to increase a bulk density of the processing medium thereby forming the radiopaque processing medium. The radiopaque processing medium allows excess process media to be located and characterized during X-ray inspection of an electronic device on which the radiopaque processing medium was used. The radiopaque processing medium may also be used to locate and identify flaws/defects of the electronic device based on the location of excess radiopaque processing medium. The radiopaque processing medium may also be used as an underfill material to reinforce electronic chips soldered to the electronic device.

Diamond, Louis↗

DOE OSTI2016

THE DIVERSE ORIGINS OF NEUTRON-CAPTURE ELEMENTS IN THE METAL-POOR STAR HD 94028: POSSIBLE DETECTION OF PRODUCTS OF i-PROCESS NUCLEOSYNTHESIS

We present a detailed analysis of the composition and nucleosynthetic origins of the heavy elements in the metal-poor ([Fe/H] = −1.62 ± 0.09) star HD 94028. Previous studies revealed that this star is mildly enhanced in elements produced by the slow neutron-capture process (s process; e.g., [Pb/Fe] = +0.79 ± 0.32) and rapid neutron-capture process (r process; e.g., [Eu/Fe] = +0.22 ± 0.12), including unusually large molybdenum ([Mo/Fe] = +0.97 ± 0.16) and ruthenium ([Ru/Fe] = +0.69 ± 0.17) enhancements. However, this star is not enhanced in carbon ([C/Fe] = −0.06 ± 0.19). We analyze an archival near-ultraviolet spectrum of HD 94028, collected using the Space Telescope Imaging Spectrograph on board the Hubble Space Telescope, and other archival optical spectra collected from ground-based telescopes. We report abundances or upper limits derived from 64 species of 56 elements. We compare these observations with s-process yields from low-metallicity AGB evolution and nucleosynthesis models. No combination of s- and r-process patterns can adequately reproduce the observed abundances, including the super-solar [As/Ge] ratio (+0.99 ± 0.23) and the enhanced [Mo/Fe] and [Ru/Fe] ratios. We can fit these features when including an additional contribution from the intermediate neutron-capture process (i process), which perhaps operated through the ingestion of H in He-burning convective regions in massive stars, super-AGB stars, or low-mass AGB stars. Currently, only the i process appears capable of consistently producing the super-solar [As/Ge] ratios and ratios among neighboring heavy elements found in HD 94028. Other metal-poor stars also show enhanced [As/Ge] ratios, hinting that operation of the i process may have been common in the early Galaxy.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2019

Computer–aided process intensification: Challenges, trends and opportunities

Chemicals based products and the processes that manufacture them play important roles in sustaining our society. Chemical, biochemical, petrochemical and related processes are characterized by either conversion of specific raw materials to desired chemicals or extraction of desired chemicals from specific raw materials. Well–known examples in the first category are the conversion of methanol and acetic acid to form methyl acetate and water, and, carbon dioxide hydrogenation to methanol via the reverse water gas shift reaction. In the second category, the use of de–methanizer, de–ethanizer, de–propanizer, and so on, separation steps in gas processing plants are well–known. In the conversion–based processes, as the conversions of raw materials are usually not 100% complete, energy intensive downstream separation techniques need to be employed to separate the desired products and recycle the unreacted raw materials. Note that the conversion process itself may also be energy intensive. In the extraction–based processes where product chemicals do not usually represent 100% of the raw material, energy intensive separation techniques are commonly employed to achieve the desired separations. This means that for both categories of processes, energy in different forms need to be supplied and the processes during operation have the potential to produce waste that may lead to negative environmental impacts and cause supply chain issues. Furthermore, planet earth is facing challenges with respect to energy, water, food, and environment, and significant improvements in process efficiencies of new and/or existing processes are needed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Characterization of Hot Workability of 5052 Aluminum Alloy Based on Activation Energy-Processing Map

In the design of hot forming processes for aluminum alloys, hot processing maps are usually used as a powerful tool for processing parameters optimizations. Although the stability of deformation is considered in conventional hot processing (CHP) maps, the difficulty of deformation, i.e., whether deformation is easy to occur, is not taken into account. Therefore, it is difficult for CHP maps to efficiently and accurately obtain the optimal processing parameters and achieve satisfying hot workability. Hence, in this study, thermal compression tests were performed to investigate the hot forming behavior of 5052 aluminum alloy in the deformation temperature range of 553-733 K and strain rate range of 0.001-1 s{sup −1}. We proposed an activation energy-processing (AEP) map by coupling the CHP map and the activation energy value, and thereby applied it to evaluate the hot workability of 5052 aluminum alloy. In CHP maps, the region with the highest power dissipation efficiency is generally considered to be the best processing region. However, the AEP map shows that materials with satisfying hot workability not only depends on high power dissipation efficiency, but also on low activation energy values. At the strain of 0.7, the optimal hot processing region predicted by the CHP map lies in the temperature range of 583-673 K and strain rate range of 0.001-0.1 s{sup −1}, but that predicted by AEP map locates in the temperature range of 643-733 K and strain rate range of 0.001-0.1 s{sup −1}. Microstructure characterization implies that the optimal processing region predicted by the CHP map presents necklace-like structures, which are non-uniform and unbeneficial for deformation, while that predicted by the AEP map consists of fine, uniform and equiaxed grains. Thus, it is implied that the processing regions predicted by the AEP map are more suitable for forming, i.e., the reasonability of the AEP map is verified.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Process mining for healthcare: Characteristics and challenges

Process mining techniques can be used to analyse business processes using the data logged during their execution. These techniques are leveraged in a wide range of domains, including healthcare, where it focuses mainly on the analysis of diagnostic, treatment, and organisational processes. Despite the huge amount of data generated in hospitals by staff and machinery involved in healthcare processes, there is no evidence of a systematic uptake of process mining beyond targeted case studies in a research context. When developing and using process mining in healthcare, distinguishing characteristics of healthcare processes such as their variability and patient-centred focus require targeted attention. Against this background, the Process-Oriented Data Science in Healthcare Alliance has been established to propagate the research and application of techniques targeting the data-driven improvement of healthcare processes. This paper, an initiative of the alliance, presents the distinguishing characteristics of the healthcare domain that need to be considered to successfully use process mining, as well as open challenges that need to be addressed by the community in the future.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Optimization of edge bead removal (EBR) process to enhance defect reduction in optical lithography

Defect reduction remains a critical objective in the integrated circuit manufacturing process, particularly within the highly re-entrant lithography modules where minimizing defects is crucial. Defects at the wafer edge can contaminate lithography modules and downstream processing equipment, leading to redistribution onto the wafer surface and adversely affecting overall device yield. A persistent challenge in the resist coating process is the formation of resist edge beads, driven by the strong Van der Waals attraction of excess photoresist (PR) to itself and the underlying substrate. The edge bead removal (EBR) process is a standard cleaning step designed to eliminate these edge beads and prevent potential contamination. Here, in this study, we identify the sources of EBR induced defects and additional EBR process encroachment toward edge patterning during the EBR cleaning process. This study provides a comprehensive study aimed at optimizing the EBR cleaning process to effectively eliminate EBR-induced defects, thereby enhancing overall device yield. Specifically, we identify three primary defects induced by the EBR cleaning process: rainbow-type, finger-shaped, and teardrop-type defects. Our experimental study reveals that in addition to EBR rinse time, PR cast time is crucial parameters contributing to the formation of these defects. By properly optimizing the PR cast time and EBR rinse time, we were able to remove nearly 100 % of dense clusters of defects that were easily visible even at low magnification optical microscopy throughout the wafer edge. We observed that shorter PR casting times shows edge defects caused by inefficient EBR process because of insufficient time for PR to fully settle causing superfluous PR to continue flowing toward wafer edge during EBR clearing step, leading to partial removal of PR at the wafer edge and the formation of rainbow defects. Proper optimization of both PR casting time and EBR chemistries dispense time is essential to resolve these defects, ensuring efficient EBR cleaning process and improved overall device yield.

42 ENGINEERING↗

DOE OSTI2014

Evaluation of a recycling process for printed circuit board by physical separation and heat treatment

Highlights: • The parts mounted on printed circuit board (PCB) were liberated by underwater explosion and mechanical crushing. • The crushed PCB without surface-mounted parts was carbonized under inert atmosphere at 873 K to recover copper. • The multi-layered ceramic capacitors including nickel was carbonized at 873 K to recover nickel by the magnetic separation. • The tantalum powders were recovered from the molded resins by heat treatment at 723 and 823 K in air atmosphere and screening. • Energy and treatment cost of new process increased, however, the environmental burden decreased comparing conventional one. - Abstract: Printed circuit boards (PCBs) from discarded personal computer (PC) and hard disk drive were crushed by explosion in water or mechanical comminution in order to disintegrate the attached parts. More parts were stripped from PCB of PC, composed of epoxy resin; than from PCB of household appliance, composed of phenol resin. In an attempt to raise the copper grade of PCB by removing other components, a carbonization treatment was investigated. The crushed PCB without surface-mounted parts was carbonized under a nitrogen atmosphere at 873–1073 K. After screening, the char was classified by size into oversized pieces, undersized pieces and powder. The copper foil and glass fiber pieces were liberated and collected in undersized fraction. The copper foil was liberated easily from glass fiber by stamping treatment. As one of the mounted parts, the multi-layered ceramic capacitors (MLCCs), which contain nickel, were carbonized at 873 K. The magnetic separation is carried out at a lower magnetic field strength of 0.1 T and then at 0.8 T. In the +0.5 mm size fraction the nickel grade in magnetic product was increased from 0.16% to 6.7% and the nickel recovery is 74%. The other useful mounted parts are tantalum capacitors. The tantalum capacitors were collected from mounted parts. The tantalum-sintered bodies were separated from molded resins by heat treatment at 723–773 K in air atmosphere and screening of 0.5 mm. Silica was removed and 70% of tantalum grade was obtained after more than 823 K heating and separation. Next, the evaluation of Cu recycling in PCB is estimated. Energy consumption of new process increased and the treatment cost becomes 3 times higher comparing the conventional process, while the environmental burden of new process decreased comparing conventional process. The nickel recovery process in fine ground particles increased energy and energy cost comparing those of the conventional process. However, the environmental burden decreased than the conventional one. The process for recovering tantalum used more heat for the treatment and therefore the energy consumption increased by 50%, when comparing with conventional process. However, the market price for tantalum is very large; the profit for tantalum recovery is added. Also the environmental burden decreased by the recycling of tantalum recovery. Therefore, the tantalum recovery is very important step in the PCB recycling. If there is no tantalum, the consumed energy and treatment cost increase in the new process, though the environmental burden decreases.

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