Dmitry Yudovsky

1. Dmitry Yudovsky Project Portfolio, Fall 2002 through Fall 2006 Dmitry Yudovsky, Project Portfolio, 2006

2. Project Portfolio • Lawrence Livermore National Laboratories, Summer 2006 • KDP Crystal Mitigation Machine for the National Ignition Facility • UCSD, MAE156B, Winter 2006 • Z-Microsystems Server Cooling. Corporate Sponsored Project • Lawrence Livermore National Laboratories, Summer 2005 • Numerical Optimization of High Pressure Containers • Applied Materials, Inc; Electro Copper Plating Group, Summer 2004 • Bubble removal from Liquid Delivery System • Applied Materials, Inc; Chemical Mechanical Planarization Group, Summer 2003 • Metrology Unit Validation • Improvement to Factory Automation Software Development Process • San Diego Supercomputer Center, Spatial Information Systems Laboratory • GIS HTML Viewer • UCSD Structural Engineering, Powell Lab, Professor Elgamal, Structural Health Monitoring Laboratory, Ongoing Projects • Satellite Based Structural Healthmonitoring of the Vincent Thomas Bridge • Remote Structural Healthmonitoring of Voigt Bridge 2

3. Lawrence Livermore National Laboratories.Manufacturing and Materials Engineering Division KDP Crystal Mitigation Machine for the National Ignition Facility (NIF) Architecture and HMI Development Summer, 2006 Dmitry Yudovsky, Project Portfolio, 2006

4. Damage site Mitigated site Images taken from “OSL damage test of simulated mechanical mitigation Sites on KDP” by Wren Carr, Vaughn Draggoo, Paul Geraghty, and Frank Ravizza with permission of Paul Geraghty Lawrence Livermore, 2005. Page 1 Problem Statement Background NIF (the National Ignition Facility) optics are made up of optically interesting KDP crystals. Unfortunately, after every shot, these crystals develop surface damage. This damage propagates and ruins the optic during subsequent laser shorts. Purpose Crack mitigation on KDP crystals. Extend life of $30k crystal 10-fold by removing surface cracks caused by laser damage 4

5. Lawrence Livermore, 2005. Page 2 Methods - Hardware Method: Build a high precision diamond ball end-mill to remove the specified volume. camera flexure KDP End-mill 5

6. sensors data HMI amplifier actuator USER Lawrence Livermore, 2005. Page 3 Methods – Software architecture interface Pressure switches MDI G Code 2: Stepper motor Servo motor 2 linear drives 6

7. GUI World Event Status Variable Fault Event Event driven architecture, object based. Fault Check Key stroke Motor velocity Interlock breach System event … Faulted? Change Event Lawrence Livermore, 2005. Page 4 Methods – Software architecture 7

8. Lawrence Livermore, 2005. Page 4 Results 8

9. UCSD, Mechanical and Aerospace Engineering Course 156B Z-Microsystems Server Cooling Improvement Corporate Sponsored Project Winter 2006 Dmitry Yudovsky, Project Portfolio, 2006

10. UCSD MAE 156B Project. Page 1 SPONSOR: Z Microsystems • Leading The Evolution In “Field-Ready” Computing. • Design & Manufacturing of Rugged Computer Hardware. PURPOSE: Sealed Computer Module (SCM) is overheating. Develop a cooling system that is passive and rugged. It must keep the internal temperature at 25ºC above ambient 10

11. Thermal Pad Air Dam Heat Sink Aluminum Block Top Cover Thin Grease Layer Old Design UCSD MAE 156B Project. Page 2 HARDWARE CONFIGURATION Proposed Design • IMPROVEMENTS • Eliminates About 50% of The Thermal Resistance Interfaces. • Doubles The Effective Surface Area Of The Top Panel And Localizes It Above The CPU. • Modifies Top Panel To Increase Airflow • ADVANTAGES • Passive Cooling • Does Not Require Refrigerants or Liquids. • Has Zero Degrees Of Freedom 11

12. Spacing Increasing Resistance Decreasing UCSD MAE 156B Project. Page 3 SIMULATION RESULTS Heat Sink Optimization for fin spacing (A) and thickness (T) . Coded in Matlab. Sweet Spot 12

13. UCSD MAE 156B Project. Page 4 • TEST RESULTS • At 100% system load and 23ºC ambient temperature: • SCM internal temperature rises by 23ºC from ambient • CPU core temperature rises 34ºC • Spec requirement met PROTOTYPE 13

14. Lawrence Livermore National Laboratories.New Technologies Division Numerical Optimization of High Pressure Containers Summer, 2005 Dmitry Yudovsky, Project Portfolio, 2006

15. Optimal geometry Geometry Materials Thermal loading Pressure loading Autofrettage treatment Gradient Projection Stress Analysis Lawrence Livermore, 2005. Page 1 Problem Statement Purpose Optimize cylindrical, multilayered high pressure vessels for ultra-high speed wind tunnel Background Various techniques exist for raising the overall strength of vessels (such as cannons, or canisters). This includes increasing the strength (and cost) of materials, shrink fitting concentric shells, and over straining (autofrettaging) shells. An optimal assembly with shrink fitting and autofrettaging can be found. Challenges Multivariable optimization problem with many non-linear constraints. Numerically, negative radii might be great, but the solution must be kept realistic. Method Choose Gradient projection method. Find steepest descent and project it on the set of active constraints. 15

16. r2 rn r1 rn+1 rN rN+1 unit length Po P1 1 2 n N-1 N PN+1 … r2 symmetry Pi axisymmetric d1 dn-1 dn dN dN-1 r1 r = radius d = interference or radius mismatch Lawrence Livermore, 2005. Page 2 Geometrical configuration of problem … more shells 16

17. Lawrence Livermore, 2005. Page 3 Numerical Optimization Using Gradient Projection Method • Definitions • Active set: the set of currently enforced constraints • Inactive set: set of constraints that, when violated, become active • Process • Find cost function gradient • Select active constraints • Project gradient onto active set • Go down projection gn(x)<0 gn(x)=0 Breach step Inequality constraint Projected gradient gn(x)>0 Iterative downhill search 17

18. proprietary Lawrence Livermore, 2005. Page 4 Graphical User Interface 18

19. 1.5 doubling FS about increase cost by ~10 Log Outer radius 1 0.5 400 600 500 300 400 200 300 200 100 100 0 0 T outer T inner Multilayered pressure vessel. Optimal cost varies with given require factor of safety. Obviously the cost increases, but here we see that in increases exponentially. The y axis is normalized cost on a log scale. Adding a temperature gradient during operation imposes an added stress to the assembly. We see that by greatly heating the inside of the assembly, a total diameter must be made in order to sustain the thermal stress gradient. Lawrence Livermore, 2005. Page 5 Calculation Results 19

20. Applied Materials, Electro Copper Plating Group Bubble removal from Liquid Delivery System Summer 2004 Dmitry Yudovsky, Project Portfolio, 2006

21. Applied Materials, 2004. Page 1 Problem Statement • Purpose: Bubbles form in a high pressure chem-delivery line. These are detrimental to the subsequent process. • Background: Degassers are commercially available however these bubbles are caused by a chemical reaction, not dissolved gas. So a bubble trap is required. • Challenges: Waste, startup time, and installation and maintenance costs must be minimized. This would be an upgrade to existing systems. • Method: Utilize the disparity between liquid to surface interaction. 21

22. Applied Materials, 2004. Page 2 Bubble Trap Concept waste Ideal bleed hole case delivery bubbles float up surface tension pressure force Find r to balance the two clean liquid σ ≈ 0 for gas 22

23. Applied Materials, 2004. Page 3 Bubble Trap Implementation Exit to atmospheric pressure Ended up using long, very thin inner diameter tube. Friction (and some surface tension) effects counteracted the pressure force and allowed liquid to bleed at a prescribed rate, but gas to escape very quickly. Hagen-Poiseuille: μ very small for gasses 23

24. Applied Materials, Chemical Mechanical Planarization Group Metrology Unit Validation Summer 2003 Dmitry Yudovsky, Project Portfolio, 2006

25. Applied Materials, CMP, 2004. Page 1 Problem Statement • Purpose: Applied Materials CMP leads the world in wafer planarization. However, it only makes a crude, in process metrology unit to test the quality of the polishing. External metrology must be performed; this is done by third part units. CMP System Integration was validating two competitors. My function was to test to stability, functionality, and compatibility of the this unit with our CMP hardware and software. • Challenges: • Two teams from different corporate cultures • Third party unit still in beta phase • Time constraints • Accomplishments: • Prepared and implemented test scenarios • Found and helped fix many bugs 25

26. Applied Materials, 2004. Page 2 CMP Process front end back end crude in-process metrology occurs during polishing wafers container back-end processes polishing process 1 polishing process 1 passed polishing process 1 polishing process 1 cleaning process failed metrology validation Unit of interest 26

27. Applied Materials, CMP Group Improvement to Factory Automation Software Development Process Summer 2003 Dmitry Yudovsky, Project Portfolio, 2006

28. Applied Materials, CMP, 2004. Page 1 Problem Statement • Purpose: Optimize the software development (SW) process dealing with factory automation (FA). • Background: FA for a complex machine requires keeping track of 1000’s of events, status variables, errors, logging variables, and controllable variables in the operating system of the machine. Naming and numbering of these data variables requires careful planning; no two events can have the same logical address. At Applied Materials CMP SW, a software package simplifies the actual C++ coding by generating most of the header files and event handling functions. The input to this preprocessor is a syntax based language, GCD, where each datum is defined. The file was, in turn, generated from other files written by different members of the SW team in Excel, Perl, VB, or just text. This decentralized process was very cumbersome and slow. • Solution: Create a one-source database (DB) that the entire SW team could share. The DB would be locked to one user at a time to prevent collisions, control number ranges, and allow for easy import from and export to any standard or user defined format. 28

29. Applied Materials, CMP, 2004. Page 2 Software development process data converter Old Process Events Status Variables GCD file GCD Preprocessor C++ Code update C++ code Error variables … Data (Variables, events, status reports, etc.) stored in different media (Excel, text, etc.). These require data specific converter to create a GCD file. GCD file in then compiled to C++ code. data, converter, importer New Process MS Access Database on network Events, Status variables, etc. GCD file GCD Preprocessor C++ Code Import capability Data is stored in a database that sits on a network drive. Variables can be imported from GCD file. GCD file is generated with one click. 29

30. San Diego Supercomputer Center, Spatial Information Systems Laboratory GIS HTML Viewer Development Spring 2002 Dmitry Yudovsky, Project Portfolio, 2006

31. SDSC, 2002, Page 1 Problem Statement • Purpose: Develop a web-based graphical user interface for a Geographical Information System (GIS) database. • Background: GIS is a useful tool for decision making. It facilitates the graphical representation, superposition, and spatial querying of data. • Method: Use XML, JavaScript, and DHTML to accomplish the said goal. 31

32. SDSC, 2002, Page 2 GIS Overview GIS = Geographic Information System GIS database Map generator XML SQL Browser, JavaScrpit, DHTML Images, data Vector data User interacts with GIS database through an HTML viewer. This viewer must be portable over many platforms. And it must be pretty. 32

33. SDSC, 2002, Page 3 Old Style Viewer layer list is unstructured static toolbar with limited featurs query results in pop-up window 33

34. SDSC, 2002, Page 4 New Style Viewer dynamics and hierarchal layer list minimize/move features added to windows dynamic legend 34

35. UCSD Structural Engineering Department, Professor Ahmed Elgamal Satellite Based Structural Healthmonitoring of the Vincent Thomas Bridge Ongoing Dmitry Yudovsky, Project Portfolio, 2006

36. sensors Data processing FTP Remote PC internet Local PC Data processing satellite dish DAQ Data processing UCSD Structural Engineering, Page 1 Project Overview – Vincent Thomas Bridge • Purpose: Build a a remote structural health monitoring system. Prove that off- the-shelf components can be used to do remote data gathering. • Schematic: On bridge In lab Data flow schematic 36

37. UCSD Structural Engineering, Page 2 Project Overview • Sensors: • Temperature, surface, and air • Camera • Accelerometer (red dot indicates approximate location) • Extensive Collaboration • UCSD Structural Engineering • CalTrans • Hughes Network Systems • San Diego Super Computer Center • Potential • New, more complex testbeds • Temperature to frequency response correlation http://healthmonitoring.ucsd.edu/ 37

38. UCSD Structural Engineering, Page 3 Results – Thermal Data • Data for May 2005 through February 2006 38

39. UCSD Structural Engineering, Page 5 Results – Camera Data Sunrise Single Frame http://healthmonitoring.ucsd.edu/vtb/remote/vtb_remote_imaging.jsp 39

40. UCSD Structural Engineering Department, Professor Ahmed Elgamal Remote Structural Healthmonitoring of Voigt Bridge Ongoing Dmitry Yudovsky, Project Portfolio, 2006

41. UCSD Structural Engineering, Page 1 UCSD Structural Engineering – Voigt Bridge • Purpose: Monitor Voigt Bridge with accelerometers and a camera • Methods: A camera is used to determine the location of a vehicle on a bridge. A network of accelerometers monitors the excitation cause by this vehicle along the bridge. Thus we know the location of the load and the excitation. http://healthmonitoring.ucsd.edu/voigt.jsp 41

42. UCSD Structural Engineering, Page 2 Vehicle Tracking over Voigt Bridge 42