Vol. 54, Special Issue        February 2002

Nuclear weapons

The B83 Systems Engineering group has completed development of Alt 355 for the B83 Modern Strategic Bomb. Alt 355 is a near-term field retrofit kit that incorporates design modifications to the present B83-0/1 Gas Transfer System (GTS) hardware. It is the first Alt to complete the stringent Phase 6.X process. Also, a series of field tests were conducted, in conjunction with Alt 355, using two B83 Transportation Environmental Sampling Units (TESU). Both TESU test units were equipped with a data acquisition system and used to collect vibration and shock data during a variety of transportation scenarios. The data were used to compare Stockpile-to-Target Sequence specified levels for these environments. The Stockpile-To-Target-Sequence specified environments were shown to govern and remain unchanged. (2200, 8400, 8700) Thomas Gaffney, tmgaffn@sandia.gov

Lead zirconate-lead titanate (PZT) is a key ceramic used in the production of Neutron Generator power supplies. With the loss of all external suppliers, we developed an in-house production-scale process to supply PZT. Process development spanned the chemical synthesis of the PZT through powder fabrication processes resulting in a fired ceramic. Numerous technical and ES&H hurdles were overcome to scale-up the process from the laboratory size to 10 kg production quantities. MC3422 voltage bars made from the production-scale processes have met the stringent War Reserve specifications. (14100, 1800, 2500, 9200) Steve Lockwood, sjlockw@sandiagov

A simulation-based engineering approach that integrates research, numerical simulations, code validation experiments, wind tunnel data, and flight test data was used to quantify B61 spin rate losses due to vortex-fin interaction and to define optimal fin cant angle for B61-3,4,10 ALT354. TAOS spin rate predictions, confirmed in flight tests, showed that the new fin cant angle produces improved spin rates when used in conjunction with the existing spin motor. (2100, 9100, 15400) Carl Peterson, cwpeter@sandia.gov

In support of the FY01 Acclerated Strategic Computing Initiative Normal Environment Level 1 Milestone, the ALEGRA code development team successfully completed calculation of contact fuze electromechanical operation during target impact at termination of flight for a W76 Reentry Body. This calculation showcased the Adaptive Mesh Refinement (AMR) and Arbitrary Lagrangian-Eulerian (ALE) capabilities of the ALEGRA code. (9200) Edward Boucheron, eabouch@sandia.gov

Code Management System (CMS) delivery provides a significant security enhancement to weapon code operations in Europe. The CMS project has completed a four-year full-scale engineering effort with its first full system delivery to its DoD customers. This system enables the recoding of nuclear weapons in a fully encrypted manner and greatly simplifies use and logistics issues for personnel. The complete system consists of 17 NNSA-qualified products, and several commercial computers. (1700, 2100, 2500, 2900, 5900, 6500, 12300, 14100) Doug Clark, jdclark@sandia.gov We created a highly detailed finite element model of the W76/Mk4 Reentry Body (over 3 million degrees of freedom) using the ASCI code SALINAS. Model improvements have been made using data from validation experiments. Additional experiments provided insight into variability in dynamic response of these components. We have found that as-built differences in weapon components have a significant impact on dynamic response. The variability data enable statistical tests of model validation and may also affect derivation of component environmental requirements used for design certification. (9100, 2100) David Clauss dbclaus@sandia.gov

The US Navy W76-0/Mk4 Joint Test Assembly (JTA) redesign achieved First Production Unit status last August, following a successful development flight test in February 2000. The redesign replaced sunset technology components in the existing 20-year-old JTA, which is used to test the continued conformance of a denuclearized version of the War Reserve (WR) warhead. The new JTA collects significantly more state-of-health and critical performance data from onboard the Reentry Body (RB), as part of the core surveillance program. (1700, 2100, 2500, 2900, 8400, 9100, 12300) Bill Tedeschi, wjtedes@sandia.gov

A seemingly impossible fabrication task often leads to enhanced creativity. The Advanced Systems Group 2254, located at Livermore, Calif., expressed the need for a small tube-assembly consisting of very intricate components. A team from center 14100 met the following challenges: Design and fabricate a tube within a tube (thin wall-thickness); create features of very high aspect ratios (diameter versus length); manufacture micro-size grooves and angled holes (alignment / assembly); assemble components to provide a high-pressure seal (assembly/welding). Lothar Biegs, lfbieg@sandia.gov Sandia surveillance departments were key participants in the NNSA Strategic Review of the Surveillance Program (the 150-day study) and major contributors to the final report. This study will guide the future NNSA Surveillance program whose goals are to ensure that no defects in the stockpile go undetected, to uncover precursors of aging early to allow adequate time to implement corrective action, and to address other vital stockpile isses. The study and its recommendations have been accepted by DOE, and an implementation strategy has been developed. (2900) Bill Norris, wlnorri@sandia.gov

The B61-4 Type 3E Trainer is a system that the US Air Force will use to practice loading and handling operations. The Warhead Simulator Package is a key component of the Trainer, which simulates the electrical functionality of a real War Reserve weapon. The new trainer provides a significant improvement by allowing DoD personnel to realistically practice performing lock/unlock and prelaunch arming/safing operations without exposing a real nuclear weapon to vulnerabilities. The First Production Unit of the Trainer has been delivered. (2100, 2300) James Harrison, jamharr@sandia.gov

The Weapons New Hire Orientation Program was developed to provide a basis for early career development in the presence of increased hiring. The program gives new technical hires in the weapons program an unclassified basis of knowledge in Sandia's capabilities and missions, engineering processes, emerging technologies, basics of the DoD/DOE relationship, and national security strategy. (2900) John Shaw, jdshaw@sandia.gov

Sandia's largest construction project, MESA (Microsystems Engineering and Sciences Applications), continues to move at a fast pace, completing preliminary design in FY01. Six reviews led the way for projected approval of the $400 million-plus baseline, authority to proceed to final design, and subproject construction in FY02. The MESA complex is the heart of Sandia's investment in microsystems research, development, and prototyping activities. (1900, 10003, 10505, 10800) Karen Higgins, klhiggi@sandia.gov

Sandia has developed its first custom microprocessor architecture, the Sandia Secure Processor. With emphasis on surety, the design is proceeding with the goal to apply mathematically provable methods for verifying flawless, secure operation. Synthesis of the current model has yielded a 50MHz design with 40,000 logic elements that is presently undergoing extensive testing. The processor is planned for fabrication in a rad-hard technology at Sandia's Microelectronics Development Laboratory. (2100, 1700, 5900) Greg Wickstrom, glwicks@sandia.gov

Work was completed to qualify the B61-11 bomb as meeting all requirements, resulting in its acceptance as a "standard stockpile item" for the nuclear deterrent force. In recognizing the efforts of the B61-11 certification team, CINCSTRAT cited the weapon's many advantages over the retired B53-1 bomb. Also, alterations (ALTs) have been made to enhance the safety and security of B61 bombs at field locations. B61 ALT335/339/354 Production Milestones were achieved this year with the shipment of kits to support all B61s deployed outside of the US. (2100, 2600, 2300, 1800, 9100) James Harrison, jamharr@sandia.gov

The EV-C (Escort Vehicle, Class C) development team established signed requirements with NNSA's Office of Transportation Safeguards. The development team competitively selected a manufacturer to work with Honeywell and delivered a working testbed vehicle. The team also completed initial communications system integration and testing, prototyped installation of all hardware and cables, and contracted for a pre-production unit to be delivered last December -- all while reducing the overall end-to-end development cycle time by one-third. (5800) Jake Deuel, jkdeuel@sandia.gov

Emerging microsystem technologies are being explored to improve the nuclear weapon stockpile by enhancing existing systems and enabling new system architectures. Sandia successfully built the first of a series of product vehicles that will focus the maturation of war reserve-quality microsystem technologies and engineering methods. We demonstrated common hermetic packaging for mechanical, electrical, and optical microcomponents, precison alignment of optics and a SUMMiT' micromachine, die attach, wirebonding, multi-level electrical interconnects, and process integration of the above. (1700, 2300, 2600, 2900, 9100, 12300, 14000, 15300) Frank Peter, fjpeter@sandia.gov

At the successful conclusion of a three-year testing and evaluation program a Major Assembly Release (MAR) authorized on Jan. 24, 2001, the unconditional use of the Alt 342 W87 Life Extension Program (LEP) warhead by the Air Force. The Nuclear Weapons Council has accepted the W87 LEP as a standard stockpile item. (8200) C. Martin Hinckley, cmhinck@sandia.gov.

LIGA metallic and polymeric microstructures were prototyped for first use as critical components in a positive valve indicator (PVI) in preparation for inaugural flight testing next year. The key element of the PVI is an actuator-microbridge-isolator assembly that indicates positive valve functioning via a loss of electrical continuity. This assembly was packaged into a precision-machined housing and successfully tested. The prototyping was accomplished by the LIGA micro- systems team, and the design, packaging, and testing of the assembly were done by the CA weapon intern team. (8700) Craig Henderson, cchende@sandia.gov

Sandia has initiated a $100 million program to restore its Directed Stockpile Work test capabilities and to field qualification, weapon development, and model validation capabilities for the 21st century. NNSA/NA-11 approved the Justification of Mission Need in July and commissioned the development of the Conceptual Design Report that lays the foundation for the facility design efforts. The Test Capabilities Revitalization project team is well on its way to providing revitalized test facilities with leading-edge capabilities. (9100, 10800, 2100, 2200) Mike Valley, mtvalle@sandia.gov

Weaponeers should spend time innovating technology, not reviewing hundreds of nontechnical requirements and figuring out what to do next. Weapon Requirement Integration Dept. 9821 has partnered with Labs weapons experts to synthesize requirements and create short simple processes for new and refurbished weapons. The department also is leading a weapons complex-wide team to modernize Engineering Procedures into Technical Business Practices and add Infrastructure Business Practices for interface implementation details. (9800, 2100, 2200, 2300, 2600, 2900, 8400, 12300) Mark Dickinson, mddicki@sandia.gov

The DOE Weapons Complex standards laboratories will benefit from improved accuracy -- exceeding one part in a million -- in ac voltage calibrations, as well as reduced calibration expenses, thanks to microfabricated thin-film multijunction thermal converter standards designed by the Primary Standards Laboratory and fabricated in the Compound Semiconductor Research Laboratory. Vacuum sealing by the MDL using non-evaporable getters welded to the package lid increases the sensitivity an order of magnitude beyond conventional thermal converters. (2500, 1700) Thomas Wunsch, tfwunsc@sandia.gov

Model Based Reliability An alysis (MBRA) uses a combination of simulation and reliability methods to provide both qualitative and quantitative insights into reliability for both existing weapons and new development hardware. In support of enhanced surveillance activities, the MBRA process was applied to the electrical system of the W80 warhead taking advantage of the CPlant distributed computer platform. The capabilities provided by MBRA can be applied to surveillance activities including design margin analysis, specification limits, lifetime predictions, and anomaly investigation. (12300) Tom Brown, tdbrown@sandia.gov

In January 2001 Sandia responded to a US Air Force "Dull Sword," a low-level incident involving a nuclear weapon. The incident occurred when uncharacterized electrical energy surged through a Minuteman III missile weapon system in its silo. Sandians immediately responded with engineering support from several organizations. Deploying on site, the Sandians assisted in the evaluation and disposition of the warheads. There was no apparent damage to the warheads, and they have been safely transferred to DOE/NNSA custody awaiting further disassembly and inspection. Sandia continues to guide the warhead inspection effort. (2100, 2900, 12300) David Olson, drolson@sandia.gov

Since adopting Lockheed Martin's Lean/Six Sigma project management approach, Neutron Generator Production Center 14400 has seen: a 50 percent reduction in MC4277 neutron tube frame defects; a 66 percent reduction in piece part and fixture packaging time; a 33 percent reduction in neutron tube exhaust cycle time; and reduction in work in process and cycle times due to implementation of "pull." An operational goal of producing 80 neutron tubes per month for three consecutive months was achieved in October through December of 2001. Center 14400 intends to implement Lean/Six Sigma into all aspects of neutron generator operations and business practices. (14400) Ruben Muniz, rbmuniz@sandia.gov

Last modified: February 28 , 2002

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