John Saurwein February 6-7, 2001 Naval Research Laboratory, Washington IFE Target Process and Characterization Methods Development and Target Manufacturing Quality Control

Topics Summary of FY01 tasks - Target characterization methods development - High-Z overcoat process development Conceptual QC approach for IFE target manufacturing IFE target QC considerations influencing IFE target development activities - Target design - Target process development - Target characterization methods development

3.5.4 Characterization of foam shells FY01 Workscope: Develop foam shell characterization methods needed to demonstrate meeting NRL specs. - Dimensions and density of bare shells and overcoated shells - Wall thickness variations - Areal density and density fluctuations - Initial emphasis will be on methods to characterize transparent foam Support DVB foam shell process development Objective: Develop methods to characterize IFE targets. Characterize foam shells under development - $265K

High-Z overcoat for radiation preheat target FY01 Workscope: Evaluate processes for depositing high-Z overcoat on targets Determine process specs. for achieving desired properties - Thickness (325 Å ± 50 Å) - Uniformity (± 10%) - Reflectivity (TBD) - Permeability (TBD) Develop characterization methods Objective: Develop high-Z overcoat processes - $100K Place holder for picture of sputter coater

Conceptual QC approach for IFE target manufacturing Set process parameters Process step Characterize product Evaluate data Product Acceptable? Next Process Adjust parameters Process data Product information No Yes Reject Utilize statistical process control (SPC) for early detection of process or target quality problems and automatic adjustment of process parameters Minimizes fabrication of unacceptable targets Avoids cost of processing unacceptable material Ensures target availability

Evolution of QC during IFE development Continuously improve target quality and yield Control product quality with SPC and limited acceptance testing ________________________________________________________ Implement and justify reduced sampling/inspection Demo adequacy of QC methods to ensure long-term reliability of processes ________________________________________________________ Characterize targets for ETF; implement SPC and demonstrate process capability Complete development of IFE target QC methods Finalize target specifications ________________________________________________________ Characterize targets for NIF and IRE Develop performance specifications and demonstrate proof of principle for IFE target QC methods ________________________________________________________ Identify candidate QC methods for mass production Develop target characterization methods to support target process development

A comprehensive set of IFE target specifications are needed Design calculations Process capability Preliminary specifications Public and plant safety considerations Cost tradeoffs IFE target specification QC Plan Results of ignition tests In NIF Characterization capabilities ….. avoid overly conservative requirements

IFE target fabrication processes should be QC friendly Well understood process dynamics Reasonably robust Continuous (vs. batch) processes are preferable Foam shells should be transparent …..process development should identify key process parameters and correlate them with product characteristics

New target characterization (QC) methods will be needed for IFE target manufacturing Methods are needed for handling and characterizing - foam shells - gold-coated shells - DT-filled targets Some optical techniques used for ICF targets may be adaptable for use in IFE target production Greater reliance on X-radiographic methods may be necessary Methods must be fast and low cost (automated)

Summary Target characterization method development and high-Z overcoat process development tasks are underway Target characterization methods must evolve into methods suitable for IFE target mass production - Statistical process control (SPC) - Fast and low cost methods Need for high volume/low cost QC methods must be factored into - Target design - Target process development - Target characterization methods development