Our alternate approach is to rely on numerical simulations. The example simulation I will be showing you is of a brazing process, which is just one of many processes used to manufacture neutron generators. Brazing is a high-reliability method to join two pieces, by melting a special brazing material between the two pieces to be joined. The simulation shows two representative parts of a neutron generator on a shelf in the brazing furnace. The outer walls of the furnace contain heaters that are used to heat the parts being brazed.
Colors indicate temperatures, with red being hottest and blue being coldest.
This simulation shows furnace walls heating up the parts being brazed and then cooling down over the course of two hours. Right now the braze joints are not strong enough - they are failing strength tests, and as a result, we could fall behind schedule. The concept of computer guys and operators of manufacturing equipment working closely is new for both, and the operators don't completely trust the computer guys yet. So, while we were putting the simulation of the braze furnace together, the furnace operators tried to get the brazes right with different settings for furnace heaters. After months of trying, however, they also told us that they were just making things worse.