Vol. 51, No. 3        February 12, 1999

Nuclear Weapons

Stress voids occur in aluminum metallizations as a result of stresses resulting from different rates of thermal expansion of the various materials in integrated circuits. Using a more scientific understanding of this process in integrated circuits, we have suggested processing improvements to reduce stress voids in new radar components. These changes should improve the long-term reliability of the components. A multidisciplinary approach was used, including the modeling of stress generation and void growth, measurements of stress in actual microcircuits, and characterization of voids. (1800, 1700, 8700)

A sophisticated flame spray process for fabricating a radiation shield on the MC4380 neutron generator was developed and implemented. Rigorous requirements for maximum weight of the shield competed with the minimum coating thickness required for adequate shielding. Further complications were a very tight production schedule and the need to perform numerous computer simulations and radiation tests to verify the shield's performance. The solution was to build a state-of-the-art thermal spray station capable of extremely high accuracy and reproducibility in a production environment. (1800, 14300, 14400)

The time it takes for neutron generator designers to simulate the performance of their design selections has been shortened from several months to a few days by the new Web-based Neutron Generator Driver Design Tool (NGDDT). The NGDDT integrates design definition, mesh generation, finite element analysis and visualization through an easy-to-use graphical interface. The tool is presently being used by neutron generator and explosive driver designers to evaluate weight reduction options. Additional Web-based tools with enhanced design and optimization features are being developed. (1500, 9200)

In April, a neutron tube production line employee performing a routine examination discovered a crack that would allow gas to permeate into what was supposed to be a vacuum. This aspirin-sized ceramic part from an outside supplier provides an electrical path into a neutron tube. The Cermet Product Realization Team and the In-House Fabrication Team cooperated to solve the problem, delivering the first lot of War Reserve-qualified replacement parts in less than five weeks. (1400, 1500, 1800, 9100, 12300, 14300, 14400)

The Field Portable Gas Analyzer was designed, fabricated, and fielded to obtain internal dew point measurements on W80 warheads while in their stockpile locations. The results uncovered important desiccant properties that allowed a significant extension of the W80 desiccant end-of-life estimate. The budgetary impact of this project has been estimated to be in the tens of millions of dollars, primarily through relaxation of schedule and budget pressures on the W80 Stockpile Life Extension Program. (1800, 2100, 2900, 5500, 12300)

The W79 Artillery-Fired Atomic Projectile (AFAP) has been scheduled for dismantlement. Before beginning the dismantlement process, numerous activities were completed. As final reviewers, the Nuclear Explosives Safety Study review (DOE) and the Safety Evaluation review (Sandia, Lawrence Livermore, and DOE) determined that the process could proceed. The Pilot Lot for the W79 dismantlement program began in mid-1998 with the first dismantlement unit completed the first week of June 1998. The remaining Pilot Lot units were completed by the end of September 1998. (2200)

Military Liaison Center 5500 provided the impetus in reengineering the weapons spare provisioning process within DOE and DoD. Success of the program led the Air Force to make this process the business practice of the future. According to the Air Force field units, the delivery times under the new program greatly increased the availability of spares and reduced the need for on-hand inventory. The new process eliminated three layers of bureaucracy and significantly reduced costs. The team effort (AS/FM&T, DOE/AL and Military Liaison) has been submitted for the Al Gore Hammer Award. (5500, AS/FM&T, DOE/AL)

The Advanced Firing/Detonation Systems Project has demonstrated a range of advanced firing system technologies that will provide a significant increase to the level of surety for the stockpile. Recent successes include demonstrations of (1) a "Micro Firing System," an optically charged and isolated miniature firing system; (2) a "Slapper Stronglink," a miniature mechanical detonator safing stronglink; and (3) a "Direct Optical Initiation System," an advanced version of a laser-based firing set. These options are currently being considered by the Phase 6.2 studies for the W76 and W80. (2100, 2600, 2200)

The W76/Mk4 Enhanced Fidelity Instrumented-A unit will collect structural dynamics response data and investigate in-flight body dynamics. The unit was conceptualized, designed, built, qualified, and delivered in 24 months for a Navy flight test. The design includes modular telemetry in the physics package volume, and the highest data rate and battery energy density of any joint test assembly. The project involved Sandia, Los Alamos National Laboratory, Pantex, DOE/AL, Lockheed Martin, and the Navy. (2100)

FTU-12, the first flight test vehicle in the W87 Instrumented High Fidelity Joint Test Assembly development project, was successfully flown on May 7, 1998. An innovatively packaged miniaturized modular telemetry system was used for the first time to successfully acquire and transmit data both to confirm the effectiveness of the W87 ALT342 design and to lay the foundation for future high-fidelity DoD/DOE flight test vehicles. New sensor data obtained during the flight resulted in increased understanding of the W87 weapon system dynamic performance. (2200, 8400)

The Knowledge Management Program developed the first Weapons Intern Program, a two-year program of mentoring, training, projects, and rotational assignments. The next-generation weaponeers will be prepared in a fast-paced, teaming environment using a curriculum taught by experienced weaponeers and science-based technologists. The program will preserve the Labs' knowledge base essential to focusing Sandia's engineers/scientists as they prepare to meet future national security challenges. (5500)

The National Security Leadership Program was instituted to provide Sandians with a decade or more of leadership opportunities remaining in their careers with the environment and information that will enhance their ability to set Sandia's vision and direction. The multiyear, multidimensional program consists of seminars and discussions with prominent members of the national security community, site visits to key DOE and DoD installations, scenario-driven training exercises, and university short courses. The program is designed to create a richness of thoughts and opinions relevant to national security in the 21st century. (5000)

In a partnership with the CFO and CIO organizations, the Oracle Manufacturing Applications system was successfully installed, the culmination of a year-long effort. The multidisciplinary project team implemented nine complex modules: General Ledger, Inventory, Purchasing, Planning, Bill-of-Materials, Engineering, Costing, Quality, and Work-in-Process. This effort is tightly integrated with an ongoing larger effort to replace several administrative systems with Oracle Financial Applications. This effort has established a strong baseline for future growth in our overall Production Enterprise systems environment. (4400, 4800, 4900, 10300, 14300, 14400)

The B61 Radar Nose is in full-scale engineering development concurrently with AlliedSignal to support the 9/2000 DOE directed schedule. The design uses the MC4033 common radar to replace the existing 30-year-old tube type radar. The radar nose provides multiple height of burst radar fuzing, contact fuzing, and laydown shock mitigation. The project, supported by the Revolution in Engineering and Manufacturing program, is investing in modeling and simulation to augment the test and evaluation program to reduce qualification cost and cycle time. (2100, others)

In support of a May Peacekeeper flight test, we performed mass properties measurements on two Mk21/W87 Joint Test Assemblies containing full charges of insensitive high explosives. Because this quantity of explosives is not normally allowed on the California site, extensive preparation that included ES&H, transportation, security, and project personnel was required. The shipment of the units, the mass properties measurements, and related activities all were successfully accomplished, with the flight test units delivered on time to Vandenberg AFB. (2200, 8500, 8800)

Sandia has developed the first Distributed Telemetry system scheduled to be flown on an upcoming Mk21/W87 flight test in early 1999. Traditionally, some weapon system components in flight tests were replaced by the telemetry instrumentation. The new architecture subdivides telemetry functions and circuitry into smaller modules, which can be distributed throughout the test vehicle in unused spaces, so that weapon components don't need to be removed. This enhances the ability to assess stockpile reliability and safety. (8400, 2200)

Advanced shock physics diagnostics have been implemented and demonstrated on the Z accelerator. This new capability significantly extends experimental capabilities for accurate equation-of-state (EOS) measurements for stockpile stewardship applications. Preliminary shock EOS data have been obtained on aluminum to 3 Mbar and for isentropic compression of iron to over 300 kbar, which provides a significantly better determination of the iron phase transition at 130 kbar than possible with other techniques. These results have major impact on primary weapon physics and inertial confinement fusion programs. (9500)

We successfully conducted several experiments on Los Alamos National Laboratory's STAGECOACH subcritical experiment (SCE) in the U1a Tunnel Complex at the Nevada Test Site. The SCE objective is to acquire data on shock-induced properties of plutonium (Pu). Our experiments consisted of three velocity interferometry systems (VISAR) and a pyrometry temperature measurement system. The VISARs measured shock-induced ejecta from the Pu surface and shock velocities from a windowed surface of the material. The pyrometry system used three infrared bands to make a time-resolved measurement of the shock-induced temperature. (9500)

The Design to Analysis (D2A) pilot project has created full system-level analysis models of the B61-3, -4, -10, -7, and -11. Using a modular approach, solid modeling software was used to create models of all the components required for each variation. A process was developed to reduce by a factor of two the modeling and mesh generation time while improving model accuracy. The models are compatible with both CUBIT and PATRAN software. A central repository for the files with associated material properties was created. (2900, 9100, 9200)

Surety Assessment Center 12300 provided program management for Sandia's participation in the DOE Accident Response Group (ARG). In 1998, Sandia furnished planners and responders for Diagonal Glance (joint US/UK exercise) and Direct Focus (US exercise). Diagonal Glance prepared US ARG responders to work with UK responders. Direct Focus involved four accident sites with aircraft debris and nuclear weapons. The exercise simulated potentially hazardous scenarios and was one of the most complex and challenging exercises for weapon recovery operations in ARG history. (12300)

Surety Assessment Center 12300's Stockpile Surveillance Program evaluated 117 nuclear weapons in FY98. Seventy were denuclearized and tested at Sandia's Weapons Evaluation Laboratory at the Pantex Plant. Forty-seven were flight-tested with operational delivery systems. Delivery systems tested included the Trident-I, Trident-II, Peacekeeper, Minuteman-III, the three cruise missile variants, and the B-2A, B-52H, F-16C, and F-15E aircraft. Seventeen Significant Finding Investigations were opened to determine the reliability and safety impacts and appropriate corrective actions for anomalies detected. As a result, nine defects were identified. (12300)

Defense Programs Products and Services Division 14000 continues to implement strategy for a flexible and well-trained workforce. We developed a documented training plan for 98 percent of employees and graduated the first six Trades trainees from their training program more than a year ahead of schedule. In addition, we developed and implemented a training program for the seamless transition to Oracle manufacturing software. Training people in the continuous process improvement methodology has resulted in savings of more than $200,000 this year. (14300, 14400)

The W76 program continued to exceed performance expectations in FY98. Through continuous process improvement efforts the Product Realization Team saved $200,000, decreased cycle time by 20 percent, had 19 consecutive successful Quality Assurance Inspection Procedure (QAIP) submittals to DOE, gained sufficient trust of DOE to eliminate the QAIP requirement from one level of the conversion process, and decreased the budget by 17 percent. (14300, 14400, 1800, 9100, 1400, 1500, 7800)

Neutron generator subassemblies from retired weapons and other sources have been examined for reapplication to the W76/Mk4 and W78 systems. Enough assets have been identified that need minor modifications to meet near-term needs for the W78, and to reduce stress on the production facility during startup of the MC4380 neutron generator production. These units have resulted in more than $55 million of cost savings for DOE. (2100, 14300)

A prototype vehicle of the Next Generation Armor Tractor (NGAT) was completed for the DOE Transportation Safeguards Division (TSD). The requirements for the prototype were developed with TSD and include improvements in operator ergonomics, communications, and ballistic protection. Acceptance of the prototype has led to an accelerated development effort and the purchase of eight new tractors for the production effort. TSD will use the NGAT with the Safe Secure Trailer and SafeGuards Transporter for surface transport of defense cargo throughout continental United States. (6300)

Development activities for the MC4380 neutron generator have been completed. The program has moved into the Process Prove-In stage. These activities will be used to finalize and validate manufacturing processes and procedures before moving into the Qualification Evaluation (QE) stage. The MC4277 neutron tube has completed process qualification and has submitted its first QE lot for acceptance under DOE's Quality Assurance Inspection Procedure. First production unit deliveries for the MC4380 are scheduled for October 1999. (1100, 1400, 1500, 1800, 2900, 9100, 9600, 14300, 14400)

During FY98 Sandia delivered more than 20,000 components to DOE for application in nuclear weapons, including active ceramics, cermets, explosives, frequency devices, low-power pyrotechnics, lithium-ambient batteries, magnetics, microelectronics, and thermal batteries. These components were primarily manufactured by commercial suppliers; however, some were fabricated in Sandia's Manufacturing Technologies Center 1400. (1400, 1500, 1700, 14300, 14400)

Last modified: February 12, 1999

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