Vol. 52, No. 3        February 11, 2000

Nuclear Weapons

The MC4380 Neutron Generator and its MC4378 Timer, MC4705 Voltage Bar, MC4148 Rod, MC4437 Current Stack, and MC4277 Neutron Tube were qualified for use in the Navy's W76 weapon system. This culminated a multi-year development effort which included the transfer of production capability from the Pinellas Plant to Sandia. This is the first weaponized neutron generator to employ a focused ion-beam neutron tube for higher reliability, the first produced at Sandia, and the first Sandia component with radiation hardness requirements to be qualified without underground testing. (1400, 1800, 2100, 2500, 2900, 6400, 9100, 9200, 10500, 12300, 15300, 14000) (NWSBU)

We have designed and implemented a new ion beam analysis system to simultaneously measure absolute quantities of H, D, and T in neutron tube metal hydride components. The technique uses elastic recoil detection coupled with a particle telescope to provide accurate separation of elements. The system simultaneously quantifies occluder metal concentration and surface and bulk oxygen concentration using Rutherford backscattering spectrometry. (14400, 1100) (NWSBU)

When the decision was made to move neutron generator production to Sandia, transferring the brazing process from the Pinellas, Fla., facility was difficult because different equipment was used here. Thermal modeling was used in combination with limited experimentation to understand the brazing technology and to increase predictability and control of processes. Yields have increased from about 40 percent to greater than 75 percent. Simultaneously, throughput has more than doubled for the two most critical processes, and throughput for all other processes has increased by 30 percent. (14400, 9100, 1800) (NWSBU)

B61-11 alteration (ALT) 349 units were produced and delivered to the Air Force. Alt 349 is a structural modification to the B61-11 to improve performance under certain impact conditions. Qualification activities have included three cable pull-down tests, two B-2A airdrops and a horizontal actuator shock test series. Cable pull-down testing consists of suspending units 300 ft in the air from a cable above a concrete target and pulling the unit down with rockets. In addition to testing, extensive finite element modeling has confirmed test results and contributed significantly to the overall design effort. (NWSBU)

The Primary Standards Laboratory has developed a portable Josephson Voltage Calibration Standard that will be used by seven DOE NWC contractor standards laboratories to calibrate local DC voltage standards. The system generates DC voltages to 10 volts with an uncertainty of better than 30 parts per billion. The portable system will result in an improvement in the accuracy of the DC volt transfer to the DOE laboratories by almost an order of magnitude compared to current practices. (2500) (NWSBU)

The Nuclear Weapon Complex (NWC) Technical Business Practices (TBPs) were agreed upon by all of the NWC design and production agencies and approved for use by DOE/AL in July 1999. The TBPs define the NWC common Configuration Management Practices for evolving, defining, manufacturing, and controlling Nuclear Weapons Product and Equipment requirements throughout their fielded life-cycle. The TBPs replace the NWC Interagency Engineering Procedures. The TBPs facilitate more streamlined, and significantly improved, processes and procedures for achieving the goals of the product realization process -- "Better, Faster, Cheaper." (NWSBU)

The first W76 Enhanced Fidelity Instrumented-A (EFI-A) Reentry Body (RB) and Type 2G High Fidelity Flight Test Unit were successfully flown in February 1999. Sandia was the project integrator for development, building, and qualification of the flight test units. The EFI-A experiment provided valuable data using a newly designed, state-of-the-art telemetry system. The data has increased our understanding of the missile/RB interactions, internal RB shock/vibration environments, and RB dynamic behavior. The EFI-A was the first W76 flight test body to collect first-stage ignition data. (2100, 8400, 9700, 9100, 9200, 8100, 1500, 2300) (NWSBU)

In support of the Enhanced Surveillance and Dual Revalidation programs we have developed on Sandia's teraflops computer a comprehensive, coupled 3-dimensional age-aware model of the explosive firing set used in the W76 and W78 systems. We have validated it through a wide variety of materials studies and component evaluations. Using this work, we have developed a behavioral model for use in future system studies. (2600, 1100, 1800, 2500, 9200, 12300) (NWSBU)

Following a production lot failure due to an initiation problem, Sandia rapidly redesigned and validated the MC3323A thermal battery for the W80 Joint Test Assembly. Sandia used its in-house dry room operation to build, qualify, and ship 32 of the redesigned thermal batteries. Enser Corporation staff from Tampa worked alongside Sandia personnel to build the batteries and deliver them on time. (2500, 2100, 12300, 14400, 1400) (NWSBU)

The Intelligent Micromachine Department has produced an electrostatic comb actuator with 20,000 times the force per unit area of earlier designs, using Sandia's Ultra-planar, Multi-level MEMS Technology (SUMMiT V). The increase in force/area permits the use of much stiffer springs, significantly increasing the displacement and work that can be achieved and making the device far less sensitive to stiction -- the force required to cause one body in contact with another to begin to move. Both the increased capability and the reduced size and cost are significant factors increasing the actuator's applicability to both weapons and non-weapons applications. (NWSBU)

The SA3960 Permissive Action Link (PAL) Subsystem Simulator application-specific-integrated-circuit (ASIC) was developed as a key element of the Advance Code Control (ACC) architecture in support of the B61-4 Type 3E Trainer. The ACC architecture was developed to provide efficient balance between hardware and software in embedded real-time systems. The ASIC was designed and produced in little more than a year, with a cooperative effort between the systems, design, and production groups. It is the largest to date (~120K gates) produced by the Microelectronics Development Laboratory. (1700/2100) (NWSBU)

The W87 Life Extension Program is the refurbishment of the W87 nuclear warhead to enhance its structural integrity and extend its stockpile life. Several major milestones were met in FY99. The design changes were approved by the DoD Design Review and Acceptance Group in May. The Major Assembly Release was delivered to the DoD in June. (2200) (NWSBU)

Optical isolation of weapons firing sets is an integral component of modern surety themes. Sandia researchers are investigating laser triggering of the small vacuum switches called Sprytrons in the firing sets. By optimizing the laser focus and the Sprytron design, researchers reduced the laser energy required by a factor of 1,000 to 10 micro-joules. This allowed the research team to demonstrate triggering of a Sprytron through an optical fiber using a microlaser developed in Division 1000. (1100, 2100, 2600) (NWSBU/ST SMU)

The Stronglink Safety Tester: The first tester, uniquely designed to evaluate the state of health of aging safety components in the enduring stockpile, was successfully qualified at the Sandia Weapons Evaluation Test Laboratory in Amarillo, Texas. The design incorporates an automated remote mechanical unlock of the MC2935 Stronglinks, thus enabling first-time monitoring of lockup/unlock safety features at temperature. Consistent waveform analysis is provided across the weapon systems that utilize these components in their nuclear safety theme. (12300, 2600, 2900) (NWSBU)

A life extension study was conducted for the W76/Mk4 Reentry Body Assembly by Sandia, Los Alamos, DOE, Navy Strategic Systems Programs, US Strategic Command, Lockheed Martin Missiles and Space, and ITT Industries. The study identified design options, production and certification plans, and cost estimates. Sandia's conceptual design for the replacement Arming, Fuzing, and Firing (AF&F) subsystem is expected to come close to meeting the important goal of costing one-quarter of the W88/Mk5 AF&F cost. (2100, 2300, 2600, 12300) (NWSBU)

A major accomplishment of Sandia's Knowledge Management Program has been the launching of the Weapons Intern Program, a two-year work-study program to develop future weaponeers. In October, the first 15-member class -- 12 Sandians, two people from DOE/AL, and one from Allied Signal -- completed its first year, and the 21-member "Class of 2001" began with 15 Sandians, two DOE/AL, one Allied Signal, and three Air Force staff participating. Subject-matter experts from around the Labs teach, and a formal mentoring program, featuring retired experts, is included. The program received Sandia's 1999 Gold President's Quality Award. (2000, 9000, 12300) (NWSBU)

The BUSFET (Body Under Source Field Effect Transistor), a new silicon-on-insulator (SOI) device invented at Sandia, was successfully fabricated in the Microelectronics Development Laboratory. Using standard commercial silicon IC processing techniques resulting in a minimal increase in circuit cost and complexity, the BUSFET can provide total-dose hardness in excess of 2 megarads, without sacrificing the single-event upset and transient radiation hardness inherent to SOI technology. This device has application in the development of Sandia's radiation-hardened version of Intel's Pentium processor. (1700) (NWSBU)

A new approach to evaluating weapon safety in thermal accidents was developed. This approach (the FINDV code) uses the ALASKA distributed computing platform to evaluate probabilistic weapon safety for a wide range of scenarios. Thermal responses are obtained using the COYOTE code. This process was applied to the W80 warhead. Engulfing, fuel pool, and directed fires were evaluated, yielding a weapon safety profile for all these thermal challenges. This safety profile is being used to assess safety improvements in retrofit programs as part of Stockpile Life Extension Program. (12300, 9200) (NWSBU)

Confederation of Models to Perform Assessments in Stockpile Stewardship (CoMPASS) is a distributed enterprise simulation of the Nuclear Weapons Complex (NWC). The goal of this ADAPT initiative/campaign project is to improve the capabilities of decision makers to evaluate options and to craft solutions to meet Stockpile Life Extension Program design and production requirements. In FY99, CoMPASS cooperatively load-leveled the P&PD Annex E using models integrated from production partners throughout the NWC. CoMPASS also made the first distributed object application demonstration across SecureNet, operating between three NWC sites. (8100, 9800, 8900, 6200, 5800, 2900) (NWSBU)

Sandia, in partnership with former Senator Sam Nunn and the Center for Strategic and International Studies, initiated and led several task groups charged to evaluate global nuclear materials management issues and priorities and present their findings and recommendations at a major conference attended by policymakers from around the world. A senior policy panel, led by Nunn, noted that insecure and oversized nuclear weapons and materials stockpiles in the former Soviet Union, coupled with the weakening of US leadership in nuclear technologies over the last two decades, pose severe threats to US and inter- national security. The Ad-ministration and Congress are starting to follow up on these recommendations. (6400) (NWSBU)

A unique high-onset centrifuge was installed within an innovative personnel shielding system at the Sandia Weapons Evaluation Test Laboratory. The centrifuge will be used to test B61 components and, offering a testing platform not found elsewhere, can be used in other applications. Containment for centrifuges of this nature usually consists of a concrete barrier, underground excavation, or steel enclosure. Material and installation costs for these classic containment methods was estimated at $300,000. A Polycarbonate/ Unistrut containment room was developed and installed for $30,000. (12300) (NWSBU)

Two 50,000 g-lb electric drive centrifuges were installed at the Sandia Weapons Evaluation Test Laboratory. The centrifuges, which replaced two that were hydraulically driven, are used to test inertial devices in stockpiled weapons. A culmination of six years of effort, the motors and control system, consisting of the latest technology, are unique to these centrifuges. All machined parts were produced in Sandia machine shops, making this the largest project processed through Sandia shops. Sandia shop personnel also assisted in the installation. (12300, 1400) (NWSBU)

Assembled and led by Sandia, a team of Pantex personnel, Sandia staff, and professors from Cornell and Rensselaer received a 1999 Edelman Award for Achievement in Operations Research and Management Science for developing and implementing the Pantex Process Model (PPM). DOE Secretary Bill Richardson stated: "Š[T]he PPM is not only increasing the efficiency of the DOE nuclear weapons complex, but is also proving to be a valuable tool in the efforts of the US Government to significantly reduce the global nuclear danger." (6200, 9200) (NWSBU)

The ASCI DisCom2 Distributed Resource Management (DRM) team successfully demonstrated an initial resource management capability at SuperComputing '99. The prototype capability demonstrated multiple problem-solving environments using DRM services to manage and broker diverse computational resources. The DRM middleware is composed of software developed at Sandia and computational grid components from Argonne and USC. The event demonstrates the existence of a viable ASCI DRM capability that is necessary to achieve the ASCI system architecture vision of "three laboratories and one computing fabric." (6500) (NWSBU)

Nearly a year's worth of production of irreplaceable W76 gas transfer system reservoirs was saved by a stem remediation process developed by Sandia and implemented into production at the Kansas City Plant. Hardware produced at the Pinellas and Rocky Flats plants shut down during Reconfiguration was discovered to have carbon and oxide drilling deposits that affected the quality of the pinch welds that seal the tritium in the units. Savings were of the order of $10 million, and no delivery schedules to the Navy were ever missed. (8400, 8700) (NWSBU)

Multiple experimental/computational modeling activities contributed to the W76/Mk4 Joint Test Program. A detailed finite element telemetry subsystem model was used to design and qualify the unit for flight. The test unit flew successfully with no structural failures, and with telemetry providing the most detailed MK4/W76 system structural response data to date. Significant strides were made in validating a full-system structural model by comparing computational results to data from seven modal tests on W76/Mk4 and UK Trident reentry bodies. Instrumentation for magnetic flyer plate experiments was evaluated for survivability and noise reduction in harsh structural shock and electromagnetic pulse environments. (9100, 2100, 8400) (NWSBU)

A team of researchers developed a model to predict the fire-induced response of polyurethane foam. The model predicts the evolution of the material, in a non-pressurized state, and associated heat transfer as it decomposes. This capability is critical to simulating the response of nuclear, safety-critical components typically potted in organic material. This capability enhances the fidelity of numerical simulations used to predict the evolution and consequence of fires in buildings and aircraft. The project is funded by the Engineering Science Research Foundation and the experimental validation program, MAVEN. (9100) (NWSBU)

Military Liaison staff authored and performed six special repair procedures and repaired or altered more than 80 weapons in the field, spending more than 120 days at military operational sites. Some 593 Unsatisfactory Reports were received and acted upon by ML engineers. The writing staff authored 4 new publications, 23 revisions, and 71 changes to existing manuals; 1,150 students attended the wide range of technical courses offered at the Weapons Training Center. The department participated in the formation and training of the Joint Technical Operations Team, a joint DOE/DoD Explosive Ordnance program. (9400) (NWSBU)

Over the last four years, Center 9800 has provided USSTRATCOM with operational analysis and planning tools for the B61-11 earth penetrating weapon. This support has included evaluating fratricide concerns, optimizing delivery with the B-2, and working to maximize both aircraft survivability and weapon effectiveness. Most recently, Center 9800 has led an interagency group to understand more fully the weapon's penetration capabilities. (9800) (NWSBU)

The W76-1 AF&F redesign REM Pathfinder project brought together talents from 2100, 2900, and 9100 to employ high-performance computing to select from more than 300 design options. Experts in design, solid geometry modeling, meshing, computational analysis, and high-performance computing collaborated to form an exceptional design-to-analysis work flow. The effort helped us to identify areas in which we might benefit from improved tools and processes, critical for ensuring that we have the tools in place to meet our commitments to the Navy customer. (2100, 2900, 9100) (NWSBU)

Enhanced Fidelity Instrumentation (EFI) has enabled a new W87 Instrumented High Fidelity (IHF) flight test vehicle. This vehicle retains War Reserve (WR) similitude while incorporating a full suite of instrumentation allowing performance to be scored without perturbing vehicle dynamics. Analysis using data from a recent W87 IHF development test confirmed acceptable performance during second roll encounter -- a flight regime that has not been broadly understood. (2200) (NWSBU)<

Last modified: February 28, 2000

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