image of a sandia computer model/analysis of foam impacting · image of a sandia computer...

Image of a Sandia computer model/analysis of foam impactingthe leading edge of a space shuttle wing. The analysis helpedNASA in its study of the 2003 Space Shuttle Columbia accident.See page 16. (Photo by Randy Montoya)

At the end of each year, as I read the signifi-cant accomplishments our staff have submitted,I can actually begin to get a glimpse of what thefuture Sandia National Laboratories will looklike. You can almost visualize how these techni-cal achievements and process improvementscan be stacked up — brick by brick — in orderto build the laboratory of the future.

This 2004 report contains a large list ofachievements,notable for their sig-nificance and theirgreat diversity —from the creation ofsignificant ther-monuclear fusionreactions in the labo-ratory by heating andcompressing smallplastic pellets filledwith deuterium totemperatures andpressures higher thanin the sun, to the

delivery of 10 hand-held explosives sensingdevices (the “MicroHound”) to a governmentcustomer. The list stretches from “break-throughs at the frontiers of science” to “every-day” improvements in the quality of theprocesses we use to carry out research anddevelopment across the laboratories.

Two themes should be easily recognized. First, the emphasis placed by Sandians on

continuous improvements of the quality ofour processes and products is achieving majorresults. Sometimes the words “faster, cheaper,better” seem to be over-promises. (“Pick anytwo out of three” might be more realistic.) Yet,I urge you to focus on the many times whenwe are now making significant improvementsin all three at once.

Second, the emphasis and the investmentswe have made in supercomputers and model-ing and simulation are becoming a commonroute to extraordinary improvements acrossthe board. From evaluating the performance ofweapon hardware before we actually build thefirst one, to the evaluation of causes for thefailure of the Shuttle Columbia, the detailedphysics and engineering analyses played anirreplaceable role.

I invite you to review the many contribu-tions that made our year such a notable one.

C. Paul RobinsonPresident and Laboratories Director

for hostile environment electrical simulation wascompleted. Revolutionary new capabilities tomodel the response of nuclear weapon electricalcomponents in hostile X-ray radiation were demon-strated. This effort (which was also a corporate mile-stone) showcased the capability to transport radia-tion through a 3-D computer-aided design model ofa reentry body to determine dose rate in electronics,as well as the ability to simulate the performance ofan extremely complex application-specific integratedcircuit. (15300, 1700, 9200, 8200)

The Advanced Radiographic Technologies pro-gram has successfully developed and is deployinga twin-axis flash X-ray radiographic probe under-ground at the Nevada Test Site for the Armando Sub-Critical experiment. This state-of-the-art system will

A major milestone was achieved on the Micro-systems and Engineering Sciences Applications(MESA) project in FY03 with approval last May ofCritical Decision 3, the formal authorization to beginconstruction. Construction contracts wereawarded and construction is underway on both theMicrosystems Fabrication Facility (MicroFab) andMicrosystems Laboratory (MicroLab). A ground-breaking ceremony attended by our congressionaldelegation and NNSA Administrator Linton Brookswas held in August 2003 to celebrate this majorevent. (1700, 1900, 2300, 9100, 10200, 10500, 10800)

The Robust Nuclear Earth Penetrator Phase 6.2 isthe first competitive weapon feasibility study tobe initiated by NNSA and the military in more than10 years. Two teams (from 2100 and 8200) have beenformed to develop penetrator case and payload sup-port designs for B61 and B83 warheads, respectively.Accomplishments in FY03 include preparation for a2004 full-scale, proof-of-concept test, fabrication ofthe 5,000-lb penetrator needed for this test, anddevelopment of initial surety concepts andapproaches to ruggedize the arming, fuzing, andfiring set. (2100, 8200)

A new photonic proximity fuze sensor is beingdeveloped under the DoD/DOE Munitions MOUthat combines vertical-cavity surface-emittinglasers (VCSELs), resonant-cavity photodetectors,and micro-optics, and yields high single-mode opti-cal power with microwave bandwidth. The teamused flip-chip bonding of AlGaAs VCSEL epitaxialmaterial to aluminum-nitride heat sinks to obtainoutput powers above 20 mW/50 mW (continuous/pulsed) in a low-divergence beam without externalcollimating lenses. This lays the foundation for afully integrated, miniature, high-power, electricallypumped laser for DoD/DOE/Army fuzing applica-tions. (1700, 15300, 15400)

An Automated Current Stack Tabbing System(ACTS) is being developed by the Intelligent Systemsand Robotics Center for the Ceramic and Glass Dept.14192 to automate production War Reserve gluingoperations. Dept. 14192 currently performs manualgluing operations by placing small tabs onto currentstack components. To reduce part-gluing and clean-up times, the automated gluing station preciselyapplies conductive epoxy to the tab and currentstack parts with a three-degree-of-freedom roboticmanipulator. ACTS will replace human operatorsduring FY04 once the WR qualification process iscompleted. (14100, 15200)

The Accelerated Strategic Computing milestone

(Continued on next page)

Early in each calendar year the Lab News highlightsSandia National Laboratories’ principal achievementsduring the previous fiscal year. Submissions are selectedby the VPs’ offices. Numbers in parentheses at the end ofeach entry represent the Sandia center (or centers) inwhich most of the work on a particular accomplishmentwas done. The work is presented here by category. We’vefound over time that this organizational approach ishelpful, but it is important to recognize that such catego-rization, particularly in a multiprogram, multidisciplinarylaboratory such as Sandia, is to some extent arbitrary.Much of the work listed in the category “NuclearWeapons,” for example, could very appropriately havebeen listed under “Computing,” “Engineering Science,”or any one of a number of other categories. And the con-verse is certainly true. Indeed, much of the work doneacross all the Labs’ technical divisions supports Sandia’sfundamental mission-related nuclear weapons work.

For information about how to contact the researchersinvolved in the work mentioned here, contact Lab Newsstaff member Bill Murphy at [email protected].

A Note to ReadersC. PAUL ROBINSON

To all Sandians:

Sandia National LaboratoriesSandia National Laboratories is a multiprogram laboratory operatedby Sandia Corporation, a subsidiary of Lockheed Martin Corporationand a prime contractor to the US Department of Energy.

NUCLEAR WEAPONS

Sandia National Laboratories

A GRAND OPENING — Sandia and NNSA dignitaries, joined by members of the New Mexico congressional delegation,broke ground last August on the ambitious MESA project. Pictured are, from left, Sandia Senior VP Tom Hunter, NNSAAdministrator Linton Brooks, Rep. Heather Wilson, R-N.M., Sen. Jeff Bingaman, D-N.M., Sen. Pete Domenici, R-N.M.,Sandia President C. Paul Robinson, and Sandia VP Al Romig. (Photo By Randy Montoya)

http://www.sandia.gov/LabNews

Albuquerque, N.M. 87185-0165 • Livermore, Calif. 94550-0969Tonopah, Nevada • Nevada Test Site • Amarillo, Texas

Carlsbad, New Mexico • Washington, D.C.

diagnose plutonium spall strength under weapon-level loadings to benchmark design code models. Theadvanced accelerator and X-ray sources developed forthis mission are being extended in close collabora-tion with the UK’s Atomic Weapons Establishment(AWE), Bechtel-Nevada, and LANL to address bothNNSA and AWE future radiographic needs. (1600)

Sandia’s Microelectronics Development Lab set arecord fabrication time of six weeks (typically took14-18 weeks previously) to complete the digital con-troller chip (Permafrost) for the stockpile life exten-sion of the Trident nuclear weapon system. The chipwas jointly developed by Microsystems Center 1700and Electronics Systems Center 2300 and functionedproperly on the first fabrication effort (first-passsuccess). This integrated circuit is intended to operatein extreme environments (including harsh radiation)at ultra-low power consumption.

Sandia’s Primary Standards Laboratory (PSL) andthe Neutron Generator Design and Productiongroups have formed an alliance to improve thequality of tester data. Sources of measurement varia-tions and uncertainties are now more fully under-stood. The PSL has compared neutron measurements

of product. (2500, 14100, 14400)NNSA approved Critical Decision One in June

2003 to fund architectural and engineering design ofthe 29,000-square-foot LIGA Technologies Facility(LTF) at the California site. LTF is a cleanroom labora-tory building that will enable research and develop-ment on advanced LIGA microsystems technologiesto provide integrated metal, ceramic, and polymermicrosystem assemblies for national security applica-tions. Preliminary design is scheduled to be com-pleted by May, and design approval will be sought inJuly. (8500, 8700)

The W80-3 Life Extension Program team success-fully executed the first full-system nuclear safetydrop test of the new W80-3 design with supportfrom Advanced Simulation and Computing (ASC)and Weapon System Certification campaigns.PRESTO, an ASC-sponsored transient dynamic large-deformation mechanics code, was used to define thedrop test configuration and to help select instrumen-tation and instrumentation locations. The test wasperformed at Sandia’s Drop Tower Test Facility.(8200, 8700, 9100)

In March 2003 Sandia flew a W87 JTA-4 reentryvehicle (RV) and successfully tested the first wide-band (20 Mbps) data link during the Flight Test Unit17 mission. This vehicle was the most sophisticatedyet developed for a flight test at Sandia. Along withthe wideband transmitter, the RV incorporated other

The Homeland Security Display Room show-cases national security technologies in the contextof homeland defense. Last year we conducted 118tours, running the gamut from senior governmentofficials to Sandia new-hires. Program managers usethe room to show customers the full range of Sandiacapabilities. The room is unique because it displaysthe technologies in a thematic and understandablemanner that incorporates not only actual hardware,but also the concept of operations and the systemscontext for the operations. (0080, 5900)

Two Operation America events were con-ducted this past year in Hawaii and Georgia to trainbomb technicians. These events are designed,equipped, and staffed by Sandia personnel. Theycontinue to draw accolades from senior officials rep-resenting the host states and government organiza-tions. The event in Hawaii — targeting primarilymilitary personnel — was lauded by the sponsoringadmiral for its impact on his staff. The director ofthe Georgia Public Safety Training Center expressedhis gratitude in a letter to DOE Secretary Abraham.

The RoboHound, an engineering prototype,combines a sample collector, preconcentrator, androbotic vehicle to enable remote interrogation ofsuspicious items for explosives. After sample collec-tion, the operator uses a commercial chemicaldetector to check for explosives. The Mobile Robot-ics Department worked closely with the Entry Con-trol and Contraband Detection Department to inte-grate existing explosive detectors into mobilerobotic platforms toprovide explosivessampling of smallpackages. TNT andC4 were successfullycollected from awooden crate, brief-case, 20-gallondrum, and a vehiclehatch. (15200, 4100)

DOE must con-trol more than60,000 radioactivesources. The post-9/11 environmentmakes this job morechallenging thanever. Center 6800 has developed a RadiologicalSource Registry and Tracking (RSRT) system toensure that DOE has the tools to do this job. TheRSRT system provides a secure, online databasethat consolidates information on the characteris-tics, location, and ownership of DOE materials.The next phase will embed decision tools, so users

HOMELAND SECURITY

NUCLEAR WEAPONS(Continued from preceding page)


PREPARING for a W80-3 drop test at Sandia’s Drop Towertest facility. The test, done with the ASCI program, is partof the ongoing W80-3 Life Extension Program.

can assess the data and prioritize risk. (6800)

Sandia scientists have demonstrated insulator-based dielectrophoresis (iDEP) for the selectiveconcentration of live and dead bacteria. The tech-nique uses an electric field applied across an arrayof microfabricated insulating posts. The iDEP

device selectively concen-trates particles based ondifferences in polarizabilityand size. The DoD and theDepartment of HomelandSecurity are interested inthis technology for apathogen detector usingiDEP for selective concen-tration prior to protein fin-gerprinting by the liquidphase MicroChemLab.(8300, 8700)

In FY03, the Weaponsof Mass Destruction Deci-sion Analysis Center suiteof applications was

enhanced to address a broader suite of scenarios,including facility protection. Additional models forbiological and nuclear detection technologies andreach-back capabilities were developed and used tosupport WMD detection and response planningexercises as well as architecture deployment and trade-off analyses. Among accomplishments: conducted

an Alameda County (Calif.) Bio Terrorism ResponsePlan exercise and developed and conducted a simu-lation-based table-top exercise for Alameda CountyPublic Health, FBI, and other agencies. (80, 8114)

A multi-organizational team consisting of theDefense Threat Reduction Agency, DOE/NNSA labo-ratories, and industry (Northrop Grumman MissionSystems & Applied Research Associates) successfullydemonstrated unconventional nuclear warfaredefense (UNWD) capabilities at three militaryinstallations this year. The UNWD effort showcasedtechnology capable of protecting military installa-tions against unconventionally delivered nuclearweapons, improvised nuclear weapons, and radio-logical dispersal devices. (4100, 5900, 6500, 2500)

between tubes and generators and between tubetesters and generator testers, performed voltage wave-form analyses, and performed a complete uncertaintyanalysis of a tester and gas measurements supportingtube production. Control measurements have beenimplemented which are ensuring continued quality

Labs Accomplishments • March 2004

NEW MEXICO Governor and former DOE Secretary Bill Richardson, center, was one of many individuals whotoured Sandia’s Homeland Security Display Room last year. The display features many of the technologies Sandiahas developed to help the country address the threats of terrorism and proliferation. Pictured here are, from left,N.M. Secretary of Economic Development Rick Homans, Gil Baca (Sandia), Albuquerque Fire Dept. Deputy ChiefBobby Halton, T.J. Allard (Sandia), Gov. Richardson, APD Sgt. Mike Heister, Labs President C. Paul Robinson, SteveRivera (Sandia), and N.M. homeland security official R.L. Stockard.

A SANDIA-DEVELOPED isotope identification gammadetector provides enhanced security at a militaryinstallation entry control point.

ROBOHOUND interrogates a briefcase contaminatedwith explosives during an experimental test.

new technologies, including inertial measurementunits, new shock sensors, distributed wireless sensors,and GPS. Future missions will use this wideband capa-bility to gather critical data, allowing Sandia to ensurethe nation’s stockpile is in good health. (8200)

The Light-Initiated High Explosive (LIHE)Restart project team has successfully completed allof its Phase I milestones: the retraining of personnel;refurbishment of equipment; procurement of state-of-the-art instrumentation and diagnostic systems;and complete renovation of Bldg. 6715. The objec-tive of the project is to reconstitute the Sandia capa-bility that was mothballed in 1992 coincident withthe end of the cold war. The main schedule driver forthe project is W76-1 qualification testing slated forearly 2006. (2500, 10800)

The CMS is a modern Permissive Action Link(PAL) code management system supporting thenation’s PAL-equipped weapons. The CMS for theweapons in Europe was completed in 2001, and CMSis now being tailored for the weapons in the conti-nental US. We met an NNSA milestone by deliveringhost processor and cryptographic processor softwareand production keys to support initialization of CMSproducts at the Honeywell/Federal Manufacturingand Technology, Kansas City Plant. (2100, 2116,2900, 12300)

A 3-year program with an ambitious goal toimprove the surveillance data infrastructure (ISDI)was initiated during 2003. The ISDI vision is thatweapon-data users will have timely access to an accu-rate, easily understood, and complete set of data toanalyze the health of the stockpile. This program rep-resents a partnership among several centers toaddress a critical business need. Early accomplish-ments include conversion of at-risk legacy data, insti-tution of surveillance data reviews, inventory of sur-veillance data, and software improvements. (2900,2100, 2300, 2500, 8200, 12300, 9500)

The Development Joint Test Assembly (DJTA) forthe W78 Mark 12A reentry vehicle was successfullylaunched from Vandenberg AFB in September 2003.The reentry vehicle was deployed from a MinutemanIII ICBM and impacted near the Kwajalein MissileRange. The JTA6 features an advanced, modulartelemetry system with a higher data rate, improvedterminal event data noise immunity, and real-timecapture of detonator and neutron detector wave-

forms. The first production unit will be delivered tothe Air Force for its initial surveillance flight test in2004. (2100, 8200)

A significant improvement in the correlation ofneutron generator performance data taken at theSandia Weapons Evaluation Test Laboratory (WETL)with that measured in the shelf life program at Sandiahas occurred. The use ofsmall solid-state neutrondetectors with improvedcalibration techniques atWETL has provided W87,W80, and W78 neutrongenerator performance datathat were within 12 percentof the shelf life measure-ments (previously factors offour or more difference hadbeen observed). (2500,2900, 12300)

The Navy conducted thefirst flight test of a W76-1arming and fuzing systemas part of the Follow-onCommander-in-Chief Eval-uation Test (FCET) series.Early data indicate thatthe system performed itsfunctions and gatheredinformation on the reentryenvironment exactly asintended. The Arming and Fuzing System engineer-ing team has been able to integrate radar, flight com-puter, and diagnostics in a single compact assembly.The design is meeting aggressive cost goals throughuse of commercial parts, innovative packaging, andautomated production processes. (2300, 2100, 1700,1800, 2900, 15300)

We led a joint effort among DOE, Sandia, and theAir Force to finalize the System 2 interface specifi-cation, which defines the digital interface betweenaircraft and nuclear weapons. Developing compati-ble System 2 weapons will be a major improvementto the use of nuclear weapons on modern aircraft(i.e., F-35). Unique analog devices are replaced bymilitary standard digital messages. Weapondesigners can now implement advanced opera-tional concepts. The aircraft benefits from standardelectrical interface signals and test equipment. (2100,2900, 12300)

In April 2003 the W76 weapon assessment teamprovided a detailed surety analysis report of theW76-1 conceptual design. Weapon assessmentteams are cross-disciplinary teams of surety analystswho review new weapon designs and stockpiled sys-tems for nuclear safety, reliability, quality, use con-

trol, and surveillance concerns. The team shared theresults of its analyses with the W76-1 programgroup, allowing the group to focus further analysesand tests on high priority surety concerns. (12300)

The 12300 “State of the Stockpile” provides crit-ical independent assessment information to theannual stockpile certification. The reporting process

had required 12 monthsfrom research to a publi-cation in excess of 230pages. Applying theLockheed-MartinLean/Sigma toolsreduced the process tosix months and yieldeda concise 25-page report.Cost savings from theimproved process areestimated at $340,000 inthe first year and a labor-hour saving of48 percent. (12300)

The Surety Assess-ment Center conductedindependent qualityassessments on proce-dures used in stockpileweapon systems modifi-cation, realization ofWeapons Evaluation TestLaboratory equipment,

and the qualification process for Sandia-designedproducts. Results: The effectiveness of the qualifica-tion process is dependent on the knowledge andexperience of the Product Realization Team mem-bers and their interpretation of the technical busi-ness practices to conduct qualification of product.The processes in place provided sufficient guidanceto accomplish the task. Opportunities for improve-ment were noted. (12300)

Dimming Sun 03, the largest combined nuclearweapon accident response exercise in United King-dom history, featured some 2,000 representatives fromboth the UK and the US. Twenty-nine Sandians par-ticipated as part of the DOE/NNSA AccidentResponse Group. Three Sandians also helped planthe exercise. The exercise provided a realistic, chal-lenging venue for both nations’ assets to assemble,jointly organize, and execute a unified response to asimulated crash of a US aircraft carrying a cargo ofnuclear weapons in British airspace. (2100, 3100,5100, 5300, 5900, 9700, 12300, 12600, 15200)

FY03 marked the inauguration of a multiyear task tomigrate the Joint Nuclear Weapons Publications Sys-tem (JNWPS) from paper media to interactive elec-

THE PEN-X PROJECT explored two aspects of a conceptual cruise missile-penetrator weapon: addressing the difficulties ofintegrating a penetrating warhead into a cruise missile, and increasing its level of mission surety. In January at Tonopah TestRange, a large shaped charge preconditioned a Sidewinder tuff target, and a Davis gun propelled the experimental pene-trator into the target. A March experiment showed how mission surety is improved using Mission End-to-End Commandand Control, which enables the weapon to intelligently respond to unexpected threats and take commands from humansvia satellite communications. Here, Dave Paul installs the detonator in the largest shaped charge ever tested. (8200, 2500)




TESTING — Molly McCandless (2300) prepares a W76-1arming and fuzing system prototype for temperaturetesting.

DEVELOPMENTAL JTA launched from Vandenberg AFB.

Sandia began an important phase of the TOBOSprogram (Russian acronym for Safety and SecurityTechnologies for Russian Warheads) to test technolo-gies for enhanced warhead security and safety atRussian Ministry of Defense (MOD) sites. Construc-tion of a unique test bed at the MOD’s WeaponSafety and Security Technology Research Center inSt. Petersburg was completed in 2003. Initial field tri-als were initiated to evaluate monitoring technolo-gies in normal operational and storage environ-ments, extreme environmental conditions, accidentenvironments, and theft environments. (5300)

Ten MicroHound handheld explosive detec-tion units have completed acceptance testing andhave been delivered to a government customer.The MicroHound combines Center 4100’s explosivesample collection and preconcentration technologywith an Ion Mobility Spectrometer microsystemdeveloped in Center 1700. The MicroHound is one-fourth the cost, one-third the weight (12 lb.), one-half the size, and has four times more single-charge

operating life compared to competing products inthe same performance class. (4100, 1700)

A prototype anti-neutrino detector wasdeployed and tested at the San Onofre NuclearPower Station in Southern California. Data fromthe experimental series indicate this is a promisingapproach for monitoring the state of reactors.(8100)

Sandia has developed and built the first of a newgeneration of integrated microsystems for satelliteapplications. This microsystem provides a significantimprovement in performance by processing data10,000 times faster with dramatically reduced powerconsumption. This revolutionary packaging conceptintegrates a number of Sandia-developed technologiesinto a 3-D sensor package, which reduces both sizeand weight by a factor of 2,000. This technology isbroadly applicable to other sensor array applications.(5700, 1700, 1800, 14100)

Sandia pursues technical options as a means ofreducing tensions in the South Asian region. Sandiahosted retired Rear Admiral Vohra from India andRear Admiral Ansari from Pakistan to conduct jointresearch on cooperative boundary delineation,enhanced maritime trade and port security, establish-ment of a fish-ermen zone ofdisengagement,and improvedcommunicationbetween India’sCoast Guardand Pakistan’sMaritime Secu-rity Agency.Influentialretired navalofficers fromboth India andPakistan havesupported theresults of this work. (5300)

The Russian Transition Initiatives’ first commer-cial joint venture was established by teaming

TOBOS, the Russian acronym for Safety and Security Technologies for Russian Warheads, included construction of all-weather enclosure that allowed crews to repeatedly heat and remove1.5 meters of permafrost each day in order to pour the foundation of the TOBOS test facility.


tronic technical manuals. JNWPS publications containpolicy and maintenance procedures for stockpilednuclear weapons used by DoD and DOE personnel. TheTechnical Publications organization in coordinationwith DoD successfully conducted a technology evalu-ation, developed requirements, and made signifi-cant progress toward single-source publishing. FY04will consist of staff training and document conversions;FY05 will see the achievement of full capability. (2900)

A rigorous “design-to-analysis” process for thedevelopment of the structural dynamics model of theW80-LEP and shipping container was highly suc-cessful. Centers 9100 and 2900 staff contributed tothe project success through detailed planning andteamwork. The team integrated efforts in several areas:geometry simplification, element size and type, mesh-interface schemes, Patran and Cubit finite elementmodeling, element quality metrics, model check-outsimulations, and model management. (9100, 2900)

We have successfully demonstrated a novelMEMS-based acceleration switch that can sense theunique environments associated with weapon re-entry. The Silicon Reentry Sensor (SiReS) is fabricatedusing Deep Reactive Ion Etching (DRIE) and Silicon-on-Insulator (SOI) processes developed at Sandia.More than 20 prototype units have been successfullyfabricated, packaged, and tested. The project repre-sents a spiral development effort that, if successful,could result in the first Sandia-designed MEMS device

introduced into the enduring stockpile. (1700, 1800,2300, 2600, 9100, 12300, 14100, Kansas City Plant)

A partnership among several Sandia organizationsand the Kansas City Plant has successfully created sci-ence-based processes, models, and methodologiesthat will allow commercial off-the-shelf (COTS)microsystem components to be used in War Reserveapplications with high confidence. The predictive

models have been validated with accelerated testing,and the models and processes are being implementedwith parts for two ongoing Life Extension Programs,the W76-1 and the W80-3. (1700, 2300, 2600, 8200)

The first production lot of a new power supplywas accepted on schedule in February. We developedthis battery to replace a silver/zinc battery as themain JTA power source. The power supply uses com-mercially available lithium/sulfur dioxide “D” cellscontained in a rugged battery pack. Small productionlots of this power supply at EaglePicher are plannedfor the Concurrent Design and Manufacturing Pro-gram over the next several years to support NNSA

requirements. (2500, 9100, 14100)The design definition continued to mature during

the third year of the W76-1/Mk4A Life ExtensionProgram. The team passed the Conceptual DesignReview, produced development hardware, andbegan critical tests. The first evaluation of an Arm-ing, Fuzing, and Firing System passed all electricalfunctional requirements. The electrical interfacebetween the Arming and Fuzing Subsystem and mis-sile was successfully demonstrated. Fuzing hardwareto measure radar performance was delivered onschedule for FY04 flight testing. (2100, 1700, 1800,2300, 2500, 2600, 2900, 8200, 9100, 12300)

An NNSA Milestone Reporting Tool (MRT) hasbeen developed by Sandia’s Nuclear Weapons Strate-gic Management Unit. This tool tracks the status ofall negotiated Level II milestones. The MRT isavailable to all sites and site offices in the nuclearweapons complex. The tool produces site-specificinformation on each milestone that can be rolled upby a federal program manager to assess the programstatus. A formal change-control process is an integralfunction of the tool that ensures complex-wideagreement on any program changes. (9700)

A successful new enterprise has been established —the MESA Technology and Operations Prototype(MESA-TOP). The focus of MESA-TOP is to acceleratethe development of advanced microsystems for usein real-world weapons applications. The MESA-TOPteam includes experts in microsystems design, devel-opment, packaging, testing, analysis, reliability science,and systems engineering. The MESA-TOP facilityincludes offices for about 70 personnel and contains5,000 square feet of world-class cleanrooms. The facil-ity is located directly outside the Eubank Gate at 10420


NONPROLIFERATION AND ASSESSMENTS


Rear Adm. (ret.) Ravi Vohra (India)and Rear Adm. (ret.) Hassan Ansari(Pakistan) studied implementationof South Asian maritime confidence-building measures.

COTS — Commercial componentslike these are being studied for usein the stockpile.

Numotech (a US medical devices firm) with Spektr-Conversion (a Russian entrepreneurial start-up). Thejoint venture will design and manufacture medicalequipment, components, and devices, and willemploy up to 500 people, many of whom werepreviously employed in Russia’s nuclear weaponsprogram near the closed city of Snezhinsk. Sandiahas been a key player in the improvement ofNumotech’s products and in the development ofSpektr-Conversion’s technical and business infra-structures. (5300, 15200)

On March 12, 2003, the Multispectral ThermalImager (MTI) satellite exceeded its operationalmission goal of three years. This satellite is a space-based research and development project sponsoredby the NNSA Office of Nonproliferation Researchand Engineering. MTI has completed more than

20,000 orbits and has gathered more than 8,500images for a number of government researchers.Using MTI as a research and development platform,Sandia has developed a number of novel analysistechniques and tools for multispectral and thermaldata. (2600, 5700, 6500, 9600, 14100)

Sandia providedphysical protectiontraining and techni-cal expertise to theInternational AtomicEnergy Agency’s (IAEA)International PhysicalProtection AdvisoryService missions inLithuania, Ukraine,and Turkey. Sandiasupports the IAEA’seffort to prevent sabo-tage of nuclear facili-ties and theft of mate-rials from facilitiesaround the world.Also, physical protec-tion training courseswere conducted inChina for participantsfrom five countries; inthe Czech Republic for

participants from eight countries; and in Albu-querque for participants from 26 countries. (5300)

The Ares lidar, a biological weapons standoffdetection system developed for NNSA, successfullycompleted several weeks of extensive field testevaluation at Dugway Proving Ground, Utah. TheAres system was developed to provide advancedwarning of biological weapons threats and is focusedon homeland security applications. The system oper-ates in an autonomous fashion scanning the horizonand providing near-real-time analyzed inputs. InNovember, a CRADA with Smiths Detection Edge-wood was finalized to support transfer of this tech-nology to industry. (1100, 2300, 5700, 8100)

The Sandia Multispectral Analyst Remote sens-ing Toolkit (SMART) was released under govern-ment license. This remote sensing science andexploitation work focused on exploitation algo-rithms and methods targeted at the analyst. SMARTis a “plug-in” to commercial remote sensing softwarethat provides algorithms to enhance the utility of theMultispectral Thermal Imager (MTI) and other multi-spectral satellite data. This toolkit has been licensedto 22 government organizations. (5700)

Sandia has completed fabrication of the firstfunctional prototype of an enhanced opticalradiometer for the nuclear detonation (NUDET)detection payloads developed for the next genera-tion of GPS satellites. This sensor prototype has 4096optical sensors in a64x64 array. Signalsfrom this detector arrayare sampled, digitized,and processed by 256custom radiation-hard-ened application spe-cific integrated circuits(ASICs) designed andfabricated at Sandia.This NNSA-funded sen-sor integrates a numberof Sandia-developed technologies into a highly inte-grated multi-layer 3-D sensor package. (1700, 1800,5700, 14100)

The final release of the Nuclear Verification Infor-mation Tool (NVITool) was delivered to the US StateDepartment in August 2003. The NVITool was devel-oped for the Bureau of Verification and Compliancefor the Office of Nuclear Affairs (VC/NA), which isresponsible for State’s nuclear-test-verification activi-ties. A web-based product, NVITool provides a widerange of capabilities associated with collection andtracking of nuclear weapons tests and preparations.With this added capability, the tool can be used fornon-nuclear projects and workflow by other organi-zation within the State Department. (5700, 6500)

NONPROLIFERATION(Continued from preceding page)

ENERGY SECRETARY Spencer Abraham announces a com-mercial joint venture teaming US company Numotechwith Russian firm Spektr-Conversion.

DOE’s Office of Assurance and IndependentOversight (OA) conducted Security Force-on-Force exercises in October 2003 to test the pro-tection of Sandia. Sandia’sProtective Force did anoutstanding job in bothexercises. They wereassisted by many in Secu-rity who did an excellentjob of planning and settingup the operation, and thestaff in Facilities and theMotor Pool who providedsupport. Exercise observersincluded top managementfrom Sandia, NNSA/HQ,and NNSA’s Sandia Site Office, as well as stafffrom Sen. Grassley’s and Rep. Shay’s offices.(4200)

Safeguards and Security management hiredexternal experts in job task analysis, curricu-lum development, and training to help restore

SECURITYthe Protective Force training program. The Pro-tective Force Training Approval Program (TAP)was reviewed and approved by the Sandia SiteOffice (SSO), NNSA, and NNSI in September2003. SSO congratulated Sandia for submitting a“professional, well-documented TAP.” A trainingplan covering other Safeguards & Security topicalareas was also submitted and approved. (4200)

The Sandia-led Chemi-cal Defense AssessmentTeam — formed in 2000to develop defensesagainst chemical attackson Sandia/New Mexicosites — was tasked by DOEto assess several officecomplexes and to suggestdefenses. In a continuingeffort to build our techni-

cal base, we built a chemically hardened vehi-cle for security police officers, fielded animproved chemical detector, and installed pro-totypical collective protection shelters at anuclear site. Finally, we wrote a three-volumereport, “Guide to Defending DOE Sites AgainstChemical Attacks.” (4100,8100)

DEPICTION of how the Ares lidar could be deployed in urban areas for detection of biological material releases.

Mt Etna eruption, from Sandia’sMTI satellite imagery.


Recrystallization removes damage and defectsfrom a deformed piece of metal, leaving tough,ductile, perfect crystals behind. What recrystalliza-tion does is well-known, but how it begins is a long-standing mystery. Using advanced mesoscale com-puter models, we performed the first full-physics

MATERIALS, PHYSICS,AND CHEMISTRY

of approximately 30 millikelvin has been produced.This achievement opens the possibility of trappingand evaporatively cooling a large number of mol-ecules to even lower temperatures where their wavenature can be investigated. (8300)

We have made significant improvements inultra-high-temperature ceramics for use inadvanced thermal protection systems. We made fullydense ZrB2–SiC and HfB2–SiC ceramics in composi-tion ranges not previously available. These materialsmelt above 3,200°C and are strong and resistant tothermal shock. Such materials are needed to managethe 2,000°C temperatures expected from aerothermalheating of maneuverable, hypersonic vehicles thatare proposed for a number of defense, surveillance,and space missions. (1800)

Historically, the complexity of glassy polymerbehavior made it nearly impossible to evaluatedesign changes or reliability in encapsulated compo-nents without extensive experimental testing. Basedon molecular simulations (conducted with NewMexico Tech) linking a polymer's viscoelastic fric-tion to its potential energy, we developed a ther-modynamically consistent theory and 3-D analysiscode requiring no adjustable parameters to predictquantitatively the wide range of glassy polymerresponse. Our new methodology has been reportedin a series of four recent journal articles. (1800, 9100)

We have devised a general, environmentallybenign, chemical-synthesis approach to buildcomplex nanostructures that are strikingly sim-ilar to those observed in biominerals (seashellsand diatoms). The key to this new approach is tocontrol nucleation and growth events and crys-talline surface chemistry. We hope this new classof nanomaterials will lead not only to novelapplications in microdevices, sensing, energystorage and conversion, catalysis, etc., but willalso add to our understanding of how complexbiomaterials are formed. (1800)

simulations of a deformed aluminum substruc-ture. We find that one in a million tiny, pre-existingcrystallites grows quickly and large, supplying thenucleus for recrystallization. These observations pro-vide the basis for a new, physically based under-standing of this pervasive metallurgical process. (1800)

Stress in mixed silicon/germanium films, grownunder precisely controlled conditions, causes thespontaneous formation of remarkable nanoscalequantum dot molecules in square fortress-likeshapes with highly uniform sizes. The special elec-tronic properties of such solid-state “molecules”could lead to revolutionary quantum computingdevices with logic, storage, and wiring elementsthat actually build themselves. Furthermore, afocused ion beam can selectively seed the self-assembly process, demonstrating the potential tocreate complex nanoscale circuits exactly where wewant them. (1100)

Metallic photonic crystals were fabricated at San-dia’s Microelectronics Development Laboratory thatexperimentally demonstrated that thermally excitedemission from metallic 3-D photonic crystals canexceed the values predicted by Planck’s law forplanar emitters over particular temperature rangesand for a relatively narrow band of wavelengths.Potential applications could include thermal to elec-tric energy-conversion devices. (1700, 1100)

We have adopted a novel approach using engi-neered defects and newly developed analytical tech-niques to unravel the mysteries of how localizedcorrosion initiates in aluminum. We’re generatingmechanistic information by comparing the charac-teristics of nanometer-length scale degradationprocesses in synthesized protective oxide structures

with that in actual alloy systems. Theknowledge we’re gaining is a critical

component in our ongoingeffort to develop predic-

tive models of materi-als aging. (1800, 1100)

Using a crossedmolecular beamapparatus, Sandia sci-

entists, in collaborationwith Prof. James Valentiniof Columbia University,

have cooled molecules bycollisions. A single collision

between an atom and a moleculemoving at supersonic velocities has

produced molecules almost stationary inthe laboratory. By picking the appropriate collisionenergy, a cloud of molecules having a temperature

Electronic and mechanical parts often con-tain interfaces between dissimilar materials.Such interfaces often crucially affect overallmaterials strength of a part. We have discov-ered a totally new structure for such inter-faces, with perfect metal on both sides separatedby a single layer of specially arranged metalatoms. This single layer contains an intricateperfect array of nanoscale dislocations that mateto the two different bulk metals. This structurepromises to provide an extremely strong shear-resistant bond. (8700)

Motor proteins are molecular machines thatenable many materials-assembly and actuationfunctions in living organisms, including celldivision, organelle transport, and muscle con-traction. We are exploring the use of theseactive proteins to assemble and reconfigurenanomaterials in artificial systems. As a first step toward creating programmable nanomaterials, we havedemonstrated that the motor protein kinesin can transport inorganic materials such as gold nanoparticlesand quantum dots in lithographically patterned microfluidic channels. (1100, 1700, 1800)

We have developed a novel computational and experimental approach to the determination ofmembrane protein structures and dynamics in a native membrane environment. The approach employedchemical crosslinking, proteolysis, and mass spectrometry to determine a set of nine pairwise interatomicdistances in rhodopsin, a membrane protein critical to the vertebrate visual signal transduction pathway.These pairwise distances were used in conjunction with computational tools developed at Sandia for theconstruction, optimization, and simulation of membrane protein structures to determine the transmem-brane domain structure of rhodopsin at moderate resolution. (8100, 1100, 1800, 8300, 9200)

BIO/NANO/COGNO


IN A 3-D computer simulation, tiny crystallites (dark blue)grow at the expense of their neighbors, providing nucleifor the recrystallization process.

ATOMIC force micrographof a corroding nanocrys-talline Al film.

BIO-INSPIRED— This figure shows seashell-like zinc oxide(colored in the middle) and diatom-like silicate crystals(black and white).

VELOCITY-MAPPED ion image for collisions between nitricoxide and argon. The intense spot at the top of the scat-tering sphere is the result a collapse of the velocity spreadsof the molecular beams for those molecules whose scat-tered velocity vector cancels the center-of-mass velocity ofthe collision pair, thereby forming a cloud of molecules.

INTERFACE — (a) shows an experimental (gray scale)picture of the nanoscale dislocation array along with amatching theoretical (colored) picture of the structure. (b) shows a schematic diagram of the perfect array ofnanoscale dislocations which are interwoven to lock thetwo bulk metals together.

Design of the Red Storm supercomputing systemwas completed in a joint effort with Cray Inc. Witha peak speed of more than 40 trillion operations persecond, Red Storm will be the world’s fastest com-puter when delivered in the fall of 2004. This 10-fold increase in computing capability over Sandia’scurrent system will enable dramatically enhancedsimulations of weapons performance and safety,leading to important new insights in stockpile stew-ardship. (9200, 9300, 9900, 9100, 8900)

3-D resistive magnetohydrodynamics (MHD)modeling implemented in Sandia’s ALEGRA codehas been used to simulate Z-pinch wire array implo-sions at levels of detail never before attempted.Nonuniform plasma streamers like thoseobserved experimentally have been computed andcan be understood in terms of interactions betweenlocal and global magnetic field topologies. Such newphysical insights into these phenomena, gained bycollaboration of computational physicists and exper-imentalists, are critical to scaling up to higher cur-rents and radiation pulses on Sandia’s Z machine.(9200, 1600)

The new Supercomputer Annex (SCA) wasbuilt in preparation for the Red Storm computingsystem. This ~20,000-square-foot facility will provideup to seven megawatts of electrical power and 4,000tons of cooling. Additionally, a network infrastruc-ture for Red Storm was developed and will provide atotal of 1.2 terabits of switched capacity. (9300,10800)

An essential ADAPT milestone was reached with ademonstration of the secure collaborative engineer-ing and manufacturing environment being devel-oped for the Nuclear Weapons Complex. Thedemonstration consisted of an eight-site classifiedvideoconference with 70 participants; the systemhas the capacity to handle up to 24 sites. This mile-stone was the first step in an overall plan that willlead to model-based qualification of War Reserveassembly at Pantex. (8200, 8900, 9900)

The Common Component Architecture wasfounded in 1998 as a grass roots organization ofDOE laboratories and universities dedicated to devel-oping a software component system for high-perfor-mance computing. Software components are anapproach to constructing computer simulationsanalogous to the way that a radio is constructedout of electrical components. In this way, mixingand matching components can create many differ-ent high-performance applications. Using pre-builtcomponents for a simulation can meet nationalneeds more quickly and bring together the knowl-edge of potentially hundreds of researchers. (8900)

Sandia’s circuit modeling code, Xyce, running onthe ASCI White supercomputer, was used to simu-late the largest circuit (14 million devices) everattempted to be modeled. Xyce is a new massively

parallel object-oriented circuit simulation code. Xycehas also been used for predictive modeling of radia-tion effects in electronics and has been applied to thePermafrost Application Specific Integrated Circuit.New time-parallel algorithms are being developed toenable long-time simulations. (9200, 1700)

Sandia researchers have worked with the CancerResearch and Treatment Center at UNM to developa methodology to computationally design morepotent inhibitors of LFA-1/ICAM-1 binding reactionthat is important to leukocyte traffick-ing. Our novel methodology is basedon the transfer of molecular designtechnology that was previously appliedto materials work. This work has suc-cessfully resulted in potential newcompounds, and we have applied withUNM to the National Institutes ofHealth to continue this work. (9200)

The Trilinos framework wasdeveloped and released tofacilitate the design, devel-opment, integration, andongoing support of mathe-matical software librariesfor modeling and simula-tion applications. A suite ofpackages including scalablesolvers and efficient imple-mentations of commonroutines are already avail-able with the framework. Trilinos wasreleased publicly on Oct. 1, 2003, andthere were more than 100 downloads inthe first month. (9200)

Sandia has a large, complex enterprisenetwork of applications, servers, data-bases, network service, router/switches,and PCs. Maintaining the integrity of thissystem is critical because it is integral toSandia’s mission work. This year a proto-type Cyber Enterprise Management(CEM) system was deployed, creating aframework for an integrated set of toolsand processes for end-to-end improve-ments in security, performance, configura-tion, and faults. A purpose-built facility,

the Integrated Network Security and Reliability Cen-ter, was completed in November 2003, enabling co-location of subject matter experts for better commu-nication, coordination, and more rapid response toevents. (9300)

Under the corporate plan for enabling wirelessnetworking for business purposes, prototype net-works have been deployed at the California andNew Mexico sites. Wireless is a key element in net-work communication advances that will enable

portable connectivity and increased functionality. Awireless security plan for corporate use of wirelesshas been approved by DOE/SSO, and limiteddeployment is scheduled to begin in 2004.

In September, Sandia’s newest High Perfor-mance Computer resources were released to theentire Sandia user community. The resources, namedInstitutional Computing Cluster, are composed ofthree Linux-based high-performance clusters total-ing more than seven teraflops in raw computationalpower and 25 terabytes total disk storage. There aretwo 256-node systems in New Mexico, and a 128-nodecluster in California. (9300, 8900)

In May, Telecommunications Dept. 9334 was the(Continued on next page)

COMPUTING


THE INTEGRATED Network Security and Reliability Center was completedin November 2003.

ALEGRA-HEDP 3-D simulation of non-uniform wire-array ablation. The isosurface illustrates how a wire's local mag-netic field regularly disrupts mass forced toward the array axis by the array's global magnetic field. Non-uniformwire ablation is seen experimentally via laser probing (see inset) and contributes to the shape of the X-ray outputfrom Sandia's Z-machine.

TIME PARALLEL methods are being developed to simulate long time-scale effects in electronics.

first large department at Sandia to obtain certifica-tion under the 2000 version of the ISO-9000 stan-dard. Using these certified processes, we completedthe upgrade to the 5ESS switch; established telecom-munications service to the MESA-TOP (EMCORE)facility; deployed the new “all-fiber” standard inBldgs. 752, 753, and 969; and activated the tele-phone firewall (Telewall). (9300)

The Engineering Sciences Analysis Process sup-ports the analysis processes used by several Labs organi-zations by providing an automated method to organizeand manage planning documents, analysis artifacts,reviews, and documentation. A development plan andinitial implementation pilot was delivered in FY03 andthe remainder of the functionality is being added. Theprocess provides a defined level of formality foranalysis work that can be managed and tracked withthe workflow tool. (9500, 9100, 8700, 15300)

Weaponeers now have nearly instant access toengineering information on our nuclear weapons

stockpile via the classified network. The NuclearWeapons information environment (NWie) portalis a secure web-based application being developedjointly by personnel from 9500, 2900, and 9900.The portal provides access to design definition draw-ings, engineering bill of materials, system summariestypically found in the Bomb Book, Major AssemblyReleases, Military Characteristics, Stockpile-to-Target-Sequence documentation, weapon developmentreports, and other resources. (9500, 2900, 9900)

The computing and procedural support infra-structure has been established that will enable Labsdesign engineers to remotely access InteractiveElectronic Procedures (IEPs) at Pantex from theirclassified thin-client or desktop computer. The IEPproject is resident at the Pantex Plant with represen-tation across the nuclear weapons complex. Remoteaccess involves connection to Pantex throughSecureNet, using authentication protocols. The pro-cedural infrastructure involves provision for helpdesk support and official documentation for systemupgrades. (9600, 9300)

The Advanced Simulation and Computing ele-ment of the Simulation Enabled Product Realization

Program achieved two major programmatic Level1 milestones to:

• Develop capabilities to predict STS hostile envi-ronment electrical response to X-rays, and

• Achieve a capability environment for Tri-labcomputing on the Q Platform at Los Alamos.

These milestones are critical steps in providingrequired applications and computing environmentto certify that the W76-1 and W80-3 Stockpile LifeExtension Programs will meet their Stockpile-to-Tar-get-Sequence requirements. (1700, 9200, 9300,8200, 8900, 9100, 9900, 15300)

A web-enabled US Savings Bond applicationwas developed and deployed, allowingemployees to manage their bond purchasesonline. Features include updating bond deductionamounts, bond types, co-owners, and beneficia-ries. The previous online capability generatedforms that were manually input by Payroll. Thenew application provides real-time input into thePeopleSoft system. Eliminating duplicate datainput reduced the administration time by97.9 percent. The application increased data accu-racy and timeliness and won a gold President'sQuality Award. (3500, 9500, 10500)

ENERGY AND INFRASTRUCTURE ASSURANCE

The Atmospheric Radiation Measurement–Unmanned Aerospace Vehicle program conductedthe first scientific flights using a new aircraft — theProteus (see above) — and an all-new instrument pay-load with satellite links, allowing over-the-horizoncontrol. Over 75 hours of flight data were collected,with flights from the DOE Cloud and Radiation Test-bed site in Oklahoma south to the Gulf of Mexico andwest to Colorado. The measurements will enable bet-

ter understanding of cirrus clouds and their role inatmospheric phenomenology. (8100, 8200)

Sandia and Lockheed Martin Missile and Fire Con-trol (LMMFC) in Orlando forged the first-of-a-kindagreement with the government of the Republic ofChina (Taiwan) that makes a win-win-win situationfor the three entities. Sandia will provide technologyto Taiwan’s geologic repository science program,

thereby helping Taiwan maintain its nuclear powerprogram and safely dispose of its spent nuclear fuel.LMMFC will fund Sandia’s work and simultaneouslyearn credit towards Lockheed’s contractual obliga-tions to the Taiwanese government. (6800)

Paul Robinson and five DOE laboratory directorspresented a Nuclear Energy R&D Action Plan inMay to Deputy Energy Secretary Kyle McSlarrow.The plan calls for activities on the part of all six labo-ratories, with Sandia acting in an integratingcapacity. The action plan recommends an emphasison higher temperature reactors that can efficientlyproduce hydrogen, advanced fuel cycles that mini-mize waste, and incorporation of advanced sensor,information, and manufacturing technologies intofuture nuclear fuel cycles for improved safety, trans-parency, and process controls. The plan recom-mends a 10-year, $10 billion research effort. (6000)

Sandia is developing key technologies to enablethe hydrogen economy. We are unlocking themechanisms of hydrogen solid-storage materialsthrough coordinated experiments and modeling, inpartnerships with universities, national labs, andindustries. We have established a multi-year engi-neering program with a major industrial partner,and a new DOE hydrogen engines project. Addition-ally, we have been assigned the responsibility to pro-vide the science needed to draft domestic and inter-national codes and standards for hydrogen

COMPUTING

The deuterium fuel in Inertial ConfinementFusion (ICF) capsule implosions has been heated totemperatures found at the center of the sun(approximately 11 million° C), as measured via X-ray

spectroscopy (see image below left) of argon dopantsin the deuterium fuel. This temperature measure-ment, coupled with measurements of the emission of2.45 MeV D-D neutrons, confirms the thermonuclearorigin of neutrons from ICF capsule experiments dri-ven by a 20 MA Z-pinch dynamic hohlraum. Scalingpredicts ideal ignition at about 30 MA. (1600)

The dynamic material properties team (1600,15300, Ktech, Bechtel) has developed a containmentsystem that can shocklessly compress materials to>1.5 million atmospheres of pressure (one-third thepressure at the center of the earth) using Z, then her-metically seal the chamber in 10 microseconds. Sixshots have demonstrated its reliability to contain haz-ardous materials, including a radioactive P32 tracer at100 rem/hr of activity. This system enables revolution-ary dynamic materials studies.

PULSED POWER AND RADIATION EFFECTS


(Continued from preceding page)


commercialization. (8300, 8700)

The 2007 EPA regulations for both light- andheavy-duty vehicles call for significant reductionsin particulate matter (PM) emissions. To meet theserequirements, industry has a critical need for new

instrumentation capable of real-time PM measure-ments with high sensitivity. Sandia’s collaborativeeffort with the National Research Council Canadaand Artium Technologies has lead to Artium’s devel-opment of a commercial instrument using laser-induced incandescence. The technology developedhas been evaluated at test facilities at Ford and Cum-mins and on-board a diesel passenger car in collabo-ration with ChevronTexaco. (8300)

The threat of bioterrorist attacks on US dairyand beef cattle can’t be ignored. BRAT™ for Dairies,a prototype biosecurity risk-assessment tool, willallow dairy owners to assess and mitigate herdrisks arising from natural and man-madehazards. Based on Sandia’s patented RAMPART™technology, this first-of-a-kind software puts thepower of risk assessment directly into the hands ofdairy owners. As each dairy reduces its own risk,risk to the US herd as a whole is also reduced.(6800, 6500)

The MELCOR Severe Accident Analysis Code,long applied to the analysis of core meltdown acci-dents in nuclear power plants, is finding new appli-cations in the area of spent-fuel pool accident evalu-ation, motivated by homeland security concerns.Recent MELCOR studies of water drain-down acci-dents have been performed to assess the potentialfor zirconium fire initiation and subsequent releaseof fission products to the environment. These stud-ies have attracted congressional attention and willbe the subject of a National Academy of Sciencesreview. (6400)

The Linear Threshold Model for the MELCORAccident Consequence Code System (MACCS) com-puter code enhances greatly the level of detail inradiation health effects analysis by taking into

account a dose threshold to ionizing radiationeffects. The Linear Threshold Model required amajor restructuring of the MACCS computer code toinclude additional dimensions to the problem. Thenew code enables the Nuclear Regulatory Commis-sion to create more efficient evacuation scenariosand better long-term plans. (6400)

Sandia, in conjunction with 44 regional industry,government, and academic partners, has establishedthe Southwest Regional Carbon Sequestration Part-nership to determine an optimum strategy for mini-mizing greenhouse-gas intensity in the Southwest. Ulti-mately, the goal is reduction of global warmingassociated with high concentration of atmospheric car-bon dioxide. The partnership is establishing a frame-work for assessing optimum sequestration strategies forthe region, and will also identify potential gaps inmonitoring and verification approaches needed to vali-date long-term storage efforts. (6100, 6010)

A Pitzer database to predict evaporative aque-ous system evolution was compiled and validatedfor use on the Yucca Mountain Project for high-levelnuclear waste disposal. This specialized thermody-namic database is used with the equilibrium specia-tion and reaction path modeling code EQ3/6.Chemical compositions of multi-component sys-tems including concentrated brines and solutionsformed by salt deliquescence are modeled. Theresults are used to evaluate the potential for wastepackage corrosion — a significant factor in overall

repository performance. (6800)

A unique concept for using Z-pinch fusion tech-nology to generate electrical power has been com-pleted. Using advanced manufacturing technology,critical components are remanufactured every 10seconds to support a high-yield fusion pulse gener-ated by a driver based on Sandia’s Z accelerator tech-nology. This radically different, yet simpler,approach to fusion energy will compete with otherfusion concepts. (6400, 1600)

Sandia has expanded its Supervisory Control andData Acquisition (SCADA) programfacilities to Bldg. 10510 in ResearchPark. This Center 5500 program,with support from several organiza-tions (4100, 5900, 6200), providesengineering solutions, education,and training to secure the controlsystems used to manage thenation’s critical infrastructures (e.g.electric power grid, water treatmentand distribution, oil & gaspipelines). The new facilities includelabs for technology demonstration,integration, training and video con-ferencing. Sandia is leveraging theseresources in its role as co-lead inDOE’s National SCADA Testbed.

Sandia researchers and theirRussian counterparts took the firstsmall steps under a new memoran-dum of understanding (MOU)between the Labs and the Kurcha-tov Institute in Moscow, signed inJanuary 2003. The ultimate goal ofthese important first steps is to createa world that is more environmen-

tally sustainable, economically prosperous, andpolitically stable. The next step will be to expandthe partnership to include multilab groups in theUS and Russia — an effort that is now also begin-ning.

A Sandia-Los Alamos team led by the Nuclear andRisk Technologies Center (6400) produced a state-of-the-art vulnerability assessment of commercialaircraft attacks on two nuclear power plants forthe Nuclear Regulatory Commission. The projectanalyzed the ability of aircraft to strike specific plantlocations, resulting structural and fire damage,effects on critical safety systems and core melting,the resulting health consequences, and options tomitigate the damage. The computational/experi-mental capabilities of Centers 9100 and 9200 werekey to the project.

A series of NRC-certification drop tests for twotransportation cask designs were successfullycompleted. The first cask was a half-scale modelTRUPACT III cask; testing was also performed on afull-scale Mixed Oxide (MOX) fresh-fuel cask. Bothtest series comprised multiple drops at differentheights, cask orientations, and temperatures. Thistesting continues the significant contribution San-dia has made to the national and internationalprograms for safe transportation of radioactivematerials. (6100, 9100)

Sandia developed and installed an electronicmonitoring tool that has continued (for more than50 days) to track temperature and pressure changes ina Coso Naval Test Range well at a depth of 3,100 feetand ambient temperature of about 193°C (379°F). Thetest data confirm improvements in reliabilityderived from utilization of manufacturer-qualified

SANDIA PRESIDENT C. Paul Robinson signs a Memorandum of Understandingwith officials from Russia’s Kurchatov Institute to cooperate on a lab-to-labbasis on a number of technologies of mutual interest.

COSO — The US Navy’s California geothermal well con-taining Sandia’s hi-temp silicon-on-insulator tool.Thesolar panels are used to power the satellite transmitterand the tool located 3,100 ft below the surface.

ENERGY ANDINFRASTRUCTURE

(Continued from preceding page)

Z-pinch power plant fusion chamber.

CARBONseq

uestrat

ion schem

es.

SANDIA’S soot team.


Sandia’s Scannerless Range Imaging (SRI) tech-nology leads the world in high-resolution 3-Dimaging. We are in the midst of providing an SRIsystem to NASA, a key to NASA’s early return toflight. SRI will allow the NASA/Sandia team to detectand quantify catastrophic damage in orbit, thus pro-viding for safe return of the crew. Also, we havedelivered a development system to the Navy forimaging through murky littoral waters. We continueadvanced work on facial recognition and seekermunitions. (2600, 2300, 2900, 1700, 5700, 5900,9200, 12300)

To say that reliably trans-mitting and collecting real-time data from a penetratortraveling through rock or con-crete is difficult is an under-statement, to say the least. In ajoint collaboration with depart-ments 2665 and 15412, an ini-tial test of a penetrator instru-ment package was conductedwith the potential to do all ofthe above. The 6.2-cubic-inchdevice measures, records, andtransmits 3-axes of accelerationdata real-time. This develop-ment is critical to enabling end-game weapon communicationsin the future. (2600, 15400)

The Defense Ammunition Center has fundedSandia for two robotic disassembly systems based ontechnologies developed under the DOE/DoD Memo-randum of Understanding program. The first system,which disassembles a projectile containing 36mines, will be part of a new Munitions Demilitariza-tion Cryofracture Facility under construction at theMcAlester Army Ammunition Plant. The second sys-tem will disassemble 8-inch rocket-assisted projec-

tiles at the Blue Grass Army Depot. These systemswill remove people from potentially fatal hazardsthat occur annually in a worldwide industry.

The Split Hopkinson Pressure Bar Facility isfully operational. The high-strain-rate materialproperties measured in this facility are provided tothe penetration community for use in selecting pen-etrator case materials, assessing the penetrability oftargets, and benchmarking material behavior modelsin codes. Through careful design and

unique methods ofpulse-shaping, thefacility is at theforefront of high-strain-rate materialstesting technologyand provides dataunparalleled infidelity and reliabil-ity. (15400)

Sled Test #1 forthe Tactical MissileSystem-Penetratorprogram was suc-cessfully con-ducted in June2003 at Sandia’s10,000-foot sledtrack. The testassessed the surviv-

ability of a weapon fuze and high-explosive package during the penetra-tion event. Predicted depth of penetra-tion was achieved, the fuze was func-tional after the test, and data weredownloaded from the internal memory. The high-explosive showed no signs of cracks or failure andthe bond with the case wall was still intact. The pen-etrator was extracted from the concrete target usinga remotely operated demolition tractor fitted with ajack-hammer.

The SnifferStar chemical sensor, a lightweight,low-power, rapid-responding chemical warfare agentsensing module for unmanned aerial vehicles, wasselected by R&D Magazine as one of the 100 mostsignificant technologies introduced in 2003. Thetechnology is a joint development between Sandiaand Lockheed Martin, funded through LockheedMartin’s Shared Vision program. In addition to theR&D 100 award, SnifferStar has been highlighted innumerous media articles and has received otherrecognition, including a Sandia team EmployeeRecognition Award. (1700)

Sandia-developed Rapid Terrain Visualization(RTV) precision mapping synthetic aperture radar,

designed for military applications, has proven valu-able a little closer to home, too. Recently, data col-lected and processed by the system have been pro-vided to the Albuquerque Mountain Rescue Council,a volunteer search and rescue group, for two recentmissions in the Sandia mountains. The RTV mapsused in both missions significantly enhanced on-the-spot knowledge of the terrain, thus helping todetermine the safest, most efficient routes to thesubject, demonstrating a real potential to help save

lives. (5900, 2300)

The first Sandia-designed-and-built satellitelaser threat warning sensor was launched intopolar orbit onboard an Air Force weather satellitefrom Vandenberg AFB in October 2003. Successfullaser illumination testing verified its detection andreporting capabilities. Validation testing over thenext year will determine the optimum satellite con-figuration to perform its Air Force mission. Anupdated warning sensor is being developed under a$15.6 million technology transfer agreement withNorthrop Grumman Space Technologies. (5700)

Personnel at Tonopah Test Range (TTR) played akey role in the successful completion of the JointAir-to-Surface Missile (JASSM) Initial OperationalTest and Evaluation (IOT&E) Flight Test Program.The test program consisted of six separate JASSMmissile launches from a B-52H over the NevadaTest and Training Range. The missiles flew pre-A ROBOTIC DISASSEMBLY system, like the one shown

here, enables safe dismantlement of aging munitions. (Continued on next page)

SLED TEST for the Tactical Missile System-Penetrator program was success-fully conducted at Sandia’s 10,000-foot sled track.

MILITARY TECHNOLOGY AND APPLICATIONS


Image of Sandiamountains producedusing Rapid TerrainVisualization (RTV)precision mappingsynthetic apertureradar.

ROBUST penetrator instrument package.

planned routes and impacted specially preparedtargets at TTR. The TTR test team collected high-speed system performance data as the missilesimpacted the targets. (15400)

Sandia’s Cognitive Systems Program strives tomodel human cognition from a psychological andphysiological basis. In FY03, in support of a DARPAprogram, cognitive models of two individual Air-borne Warning and Control System (AWACS)operators were constructed and demonstratedagreement with their human counterparts forapproximately 90 percent of the cues and contextsrecognized. Potential human errors were preventedthrough the “discrepancy detection” mechanismwhereby a human’s own cognitive model of a com-plex task was used to mitigate fatigue or distractions.(15300, 15200, 6500, 8900, 12300, 9200, 4100)

The US Navy’s Strategic Systems Programs (SP-11)selected Sandia to be its systems engineer/integra-tor for all Navy strategic weapon security loca-

tions. The Navy’sselection followedSandia’s delivery ofhigh-quality SystemEffectiveness Assess-ments (SEAs) for theNavy’s submarinebases in Bangor,Wash., and KingsBay, Ga. Sandia’s firstmajoractivity as the systemengineer was todeliver air threatanalysis reports thatprovided structural/thermal modeling ofcritical facilities ateach base. (4100,9100)

Umbra softwarebrings the besttogether for rapidlyanalyzing technol-ogy impacts. Note-worthy team accom-plishments include:analysis of distributedad hoc communications and small robotic air plat-forms on situational awareness in urban conflict(completed in three months); rapid design changesto compensate for radio shortcomings in unat-tended ground sensor networks (completed in twoweeks); and analysis of networked microsensors inurban military operations (completed in one month).(15200, 15300, 6500, 9100, 2500)

Leveraging technologies developed for nuclearweapons programs, Sandia’s Technologies for Sys-tems Analysis and Simulation group is developingan integrated, knowledge-based Support Enter-prise Modeling (SEM) capability for the JointStrike Fighter (JSF) program. The SEM capabilitywill enable Lockheed Martin Aeronautics to deter-mine the best-value JSF business approach and toassess and optimize performance/cost as the JSFprogram moves forward. An Integrated EnterpriseModeling capability is being developed thatincludes an interoperability architecture enablingthe federation of SEM with other models, tools,and databases used within the JSF program. (15300,9200, 9500, 1400, 2900)

The flight hardware for projects conducted insupport of Missile Defense and Strike Systems is fab-ricated and checked out in 15400’s Test and Assem-bly Laboratory. Major accomplishments in 2003included payload suites for Missile Defense Inte-grated Flight Test 14 and 14 Backup, Strategic TargetSystem Flight Test Units 6, 7 and 8, and Strike Sys-tems penetrator payloads for the Army Tactical Mis-sile System, including two ground tests, twopyroshock tests, and one flight test unit. (15400,2600)

The US Navy has adopted Sandia’s “Swing Free”

crane controller for its advanced shipboard cranetechnology demonstrator. Developed for movingnuclear materials and equipment, Swing Free con-trol accelerates and decelerates the crane in sucha way that little payload swing is induced. Thetechnology was enhanced for the Navy by combin-ing Swing Free with an automatic ship-motion com-pensation algorithm. In tests at port and under wayin open water, Swing Free has demonstrated highcontainer throughput. The Navy hopes the technol-ogy will enable beachside resupply of marines and

MILITARY TECHNOLOGY

AND APPLICATIONSContinued from preceding page)

THE SWING FREE controller wasdemonstrated in an open-water exercisein October 2003. While traveling atroughly three knots, the crane success-fully transferred cargo between the USSFlickertail and her sister ship, thusdemonstrating underway replenishmentcapability.

JOINT AIR-TO-SURFACE MISSILE flight tests being con-ducted at Sandia’s Tonopah Test Range in Nevada. Topphoto shows missile in flight; bottom photo showsbunker target.

UMBRA — Understanding technology impacts in evolving military conflict situations.

CENTER 15400’s Test and Assembly Laboratory.


Working under a single-laboratory/multi-partner CRADA, Sandiaand four leading bit manufacturers jointly conducted extensivefield tests that validated the hard-rock drilling capabilities of state-of-the-art drag bits and the utility of Sandia’s new Diagnostics-While-Drilling (DWD) system, which provides novel real-time downhole andsurface data for controlling the drilling process. The tests have effec-tively promoted the continued development and adoption of advanceddrag-bit and instrumentation technologies for achieving significantreductions in the drilling costs associated with difficult geothermal, oil,and gas applications. (6200)

Responding to an increased need for assessing vulnerabilities ofdams, transmission lines, water utilities, and chemical facilities, Sandiahas developed risk-assessment methodologies (RAMsSM) and vulnera-bility-assessment methodologies (VAMsSM) and streamlined proce-dures to deploy these tools through more than 200 licensees. Otherlicensed technologies with homeland security applications includedecontamination formulation, shooter identification, and microchem-lab. We have also modified the automated Work for Others system,eWFO, enabling automated, rapid processing of Department of Home-land Security proposals while meeting DOE requirements. (1300, 1700,2500, 4100, 6200, 8500, 11700)

The Sandia Science and Technology Park attracted four new tenantsin FY03: Materials Processing & Coatings Laboratory, Zia Laser, MESATOP, and Ktech Corporation. Additional highlights included RoadrunnerLevel Recognition by Quality New Mexico, the Park’s five-year anniver-sary, and the completion of the Eubank Expansion Project. The Parkboasts 16 companies and 850 employees. Total investment in the Parkexceeds $120 million. An economic impact analysis performed this yeardetermined that the Park has created more than 2,300 direct and indirectjobs, with the salary of each job averaging $45,000. (14030, 14031, 1300)

The rock blasting computer code, DMCBLAST, has been extended toinclude 3-D simulations. This work is the result of a 17-year collabora-tion with Orica USA Inc., the largest manufacturer of commercialexplosives in the US. The capabilities of DMCBLAST have driven theconversion of the US surface coal mining industry to a practice called“cast blasting” wherein surface mining blasts are overloaded with explo-sives and the blasthole-to-blasthole detonation timing is controlled tomaximize the explosively induced rock movement. (15300)

Before FY01 began, the concurrent design and manufacturing (CDM) programat Sandia had never had a full year with a perfect record of on-time, on-budgetdeliveries to NNSA/DOE. At the end of FY03, CDM had achieved a perfect recordfor three full years in which CDM delivered 93lots with a total of 11,591 components fromseven technologies, delivered to support all of theseven weapons systems at Sandia. In FY03, CDMdelivered 22 lots, with a total of 2,390 compo-nents. (14000, 1700, 2500, 2600, 2100)

The Manufacturing Working Group (MWG)was formed in early FY03 by Sandia and a widerange of industry, government, and universitypartners to identify and develop solutions onwhat New Mexico needs from its local manufac-turing supply base, focusing on Design-for-Per-formance manufacturing. Also, a committee ofthe group is developing a High Tech Manufac-turing Strategy for New Mexico. Sandia is seek-ing to strengthen its supplier base and improvethe services offered to its internal SMUs. (14000,10200)

New multi-tasking machining equipmentin the Manufacturing Enterprise has enabledreduced timelines and cost for hardwarefabrication for customers. Turning and multi-axis milling capability are combined on thesesingle machine tools. This results in reducedmachine set-up and time. For example, use ofa multi-tasking machine tool to fabricate aprototype cone ballast for the B61-11 develop-ment resulted in time and cost savings to thecustomer of 30 percent over fabrication ontraditional tools. (14100, 2100)

The Neutron Generator Production Centerheld 44 rapid improvement events in FY03 that resulted in span time reduc-

tions, yield increases, prioritization and identification of work, collaborativeteaming efforts coupled with streamlined project planning, and 6S achieve-ments. The Neutron Generator subassembly floor was recognized by Lockheed

Martin for setting the standard in 6S. Theseachievements were also highlighted in a suc-cessful presentation given to a large, receptiveaudience at the 2003 Productivity Lean Man-agement/TPM Conference in Nashville. (14400)

Developing entirely new processes, Sandia’smodel-based Product Acceptance Product Real-ization Team (PRT) achieved first-ever, model-based fabrication, measurement, submittal,and DOE/NNSA acceptance of MK-qualityproduct into the stockpile. The Division 14000PRT included members from Sandia, KansasCity/Honeywell, and DOE/NNSA. Diamondstamping the preflight controller product, byDOE/NNSA, established a milestone design-to-manufacturing capability for the nuclearweapons complex. These processes are now thebenchmark for model-based work, fully usableby PRTs choosing to employ this modern stan-dard for model-based manufacturing. (14100,12300, 2600, DOE/NNSA, Honeywell/KCP)

Sandia’s Logistics Center and Quality Assur-ance Center partnered to design, manufacture,and deliver an NNSA/Sandia Site Office-approved Nuclear-Explosives-Like-Assembly(NELA) Transport Vehicle alternative to theNNSA/Office of Secure Transportation (OST)courier services. The process improvementsresulted in a customer process time of sevendays for the new process compared to 106 daysfor the old process. Labor-hours improved to 27“touch-time” hours for the new process com-

pared to 317 hours for the old process. (8500, 12300)

TECHNOLOGYPARTNERSHIPS

MANUFACTURING AND PRODUCTION


“Time” is an important, simple-to-understandand measurable productivity improvement thateffective “integrated” and “enabling” services returnto mission organizations for mission work. Each ofus feels the pressure of not having enough time todo his or her work — with too many interruptions.In FY03, according to the IES SMU ProductivityReport, IES services and projects returned approxi-mately two hours per week per employee of timeactually given back for mission work. (7000)

Integrated Enabling Services supported threemission programs with Integrated Response Teams;delivered four new services (Integrated Moves, Inte-grated Management of Property, the IES Help Desk,and Service Finder); and supported Sandia's growthof 285 employees, 171,000 square feet of space, and$99.9 million increase in purchases with no IESbaseline cost growth. (7000)

IES/Health and wellnessIn January 2003, the Life Design Center (LDC)

opened its doors to 500-plus customers at the Cali-fornia site. The LDC serves as an auxiliary facility toBenefits and Health Services programs and services:!SALUD! health and wellness promotion; physicaltherapy rehabilitation; flu clinic; and ancillary bene-fits. Through the LDC, Sandia personnel have accessto a variety of nontraditional benefits that encour-age work/life balance and help foster a positive workenvironment. (3300, 8500)

In June 2003, the California site Health Servicesclinic earned accreditation from the AccreditationAssociation for Ambulatory Health Care. This accred-itation resulted from an intense quality effort, requir-ing an extensive project plan and collaborationbetween Centers 8500 and 3300. The clinic was eval-uated against 24 medical industry standards, andreceived a three-year accreditation — the longestincremental period possible. This achievement wasalso recognized with a Turquoise President’s QualityAward in November 2003. (8500, 3300)

IES/Human resourcesA prestigious postdoctoral fellowship has been

established by Sandia to attract the nation’s out-standing new PhDs in science and engineering.The Harry S. Truman Fellowship in NationalSecurity Science and Engineering provides theopportunity for recipients to pursue independentresearch of their own choosing that supports thenational security mission of Sandia. A team of rep-resentatives from the Staffing and UniversityResearch organizations helped define the newposition. The first fellow(s) will be selected for afall 2004 start. (3500, 1000)

whose standards were developed to encourage vol-untary attainment of high-quality care in organiza-tions providing health care services. The accredita-tion process provides rigorous clinical performancemeasurements across each health service and pro-gram and includes a thorough evaluation of theprocesses by which health care is delivered, as wellas the outcomes patients experience. (3300)

Sandia’s Hands On/Minds On Technologies Pro-gram earned a DOE “Best Practice in EqualEmployment Opportunity and Diversity,” and aNational Association of African Americans inHuman Resources “Diversity Recognition Award.”The program promotes academic achievement inminority communities underrepresented in engi-neering, science, and medicine, and a cadre of vol-unteers and role models engage 6th-12th graderswith hands-on experiences. Participants strengthenreading comprehension, scientific reasoning, andmath skills as they learn about HTML, electricity,solar power, energy, and anatomy. Former partici-pants since hired by Sandia often return as instruc-tors/volunteers. (3500, with American Indian, Black,and Hispanic Leadership and Outreach Committees)

IES/FinancialUsing a Monte Carlo simulation tool, we com-

pleted a comprehensive forecast of future pen-sion plan funding levels for Sandia’s RetirementIncome Plan. The modeling was performed toincorporate the impact of recent changes andexpected future asset returns. Sandia’s InvestmentCommittee is responsible for establishing pensioninvestment and funding policies, and the forecast-ing results were used by the Committee to re-estab-lish guidelines for allocating pension funds amongdifferent asset classes, such as stocks and bonds, inthe future. (10500)

The International Procurement Team hasachieved ISO 9001:2000 certification for its serviceprocess. The team members worked with the corpo-rate ISO group to prepare for the certification auditof this internationally recognized certification ofquality. The International Procurement Team is nowbetter able to ensure the quality of its process in acustomer-focused continuous improvement envi-ronment. (10200)

Sandia Procurement was one of four recipients ofthe Lockheed Martin “Straight to the Top” awards forits Value Stream Analysis work in Acquisition Plan-ning. Led by Procurement, this team’s work resultedin decreased cycle time, touch time, process steps,approvals, and hand-offs. Due to their tremendousfollow-through, customers experience increasedagility and decreased hassle. (10200)

The Accounts Payable Invoice Web page is aresult of feedback received from our line customers.It provides customers with a simple, user-friendlyinterface for reviewing an invoice and respondingto an invoice action. The Web page provides a one-stop venue for Sandians to query the disposition ofan invoice in one of three ways: (1) by supplierinvoice number; (2) by purchase order number; or(3) by supplier. This implementation has resulted insignificant cost savings.

INTEGRATEDENABLING

SERVICES

COMMUNITY OUTREACHOur volunteer and corporate contributions programs com-

pleted a phenomenal year with another Habitat House completed,a successful Make a Difference Day, even more Shoes for Kids, fur-ther involvement with Roadrunner Foodbank, and many other pro-jects. We have doubled our volunteer roster over the past four yearsand now have more than 3,400 registered volunteers in the pro-gram. Our corporate contributions program provided grants andgifts benefiting more than 50 community organizations with morethan 70 percent of the money used for youth and educational pro-grams and activities. (12600, Labs-wide volunteers)

Sandia’s Education Partnership programs have continued to growin scope and support. Family Science Nights (see photo at right) havegrown to more than 40 a year. Strengthening Quality in the Schools hasshown correlation to improved student performance and a lower drop-out rate, Science Bowl school participation has grown by more than 40percent. And this year we launched an essay contest, “The Write Thingto Do,” as well as our first Sandia Student Science Symposium. We con-tinue to provide leadership in community/education/business partner-ships as we continually strive to improve the quality of education andstudent performance in our state. (12600)

I.E.S.


Sandia has been recognized by the AmericanSociety for Training and Development as having oneof the 23 best training organizations in the world.The award recognizes organizations that demon-strate enterprise-wide success as a result of employeelearning and development. These organizations uselearning as a strategic tool and have the support ofsenior leaders who champion a learning culture.They have demonstrated that learning is vital toindividual and organizational performance, trainingis not a discretionary item, and even in times ofuncertainty and downturn, continued investment inemployees is the key to future success. (3500)

The annual Staffing Plan, part of the IES Inte-grated Planning Initiative, was enhanced to associ-ate hiring needs with financial projections, permit-ting Sandia to more quickly assess and respondto funding and business changes that impactstaff size. To assist with correlating financial pro-jections to headcount, a staff-planning tool wasdeveloped within the HR Graphalyzer. Informa-tion gleaned from the plan is used for external hir-ing allocations, possible retraining areas, studentemployee needs, potential temporary employeeimpacts, and other purposes. (3500)

Built on the success of the Health Services Cen-ter’s diabetes clinic pilot program, the Disease RiskManagement Clinic (DMRC) is an integrativeapproach to managing the health outcomes ofpopulations at risk for diabetes, high cholesterol,and high blood pressure. It deploys a team of Sandiahealth care professionals, contract specialists, med-ical case managers, and community providers. Withearly intervention and accessible, comprehensive,and aggressive treatment options, the DRMC pro-vides a continuum of care to Sandia employees andhas proven to make a difference in the progressionof today’s prevalent diseases. (3300)

To assure high quality in patient care, the HealthServices Center renewed its accreditation with theAccreditation Association of Ambulatory Care,

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SALUD! Program Coordinator Morgan Edwinson (withclipboard) conducts an evaluation of California sitestaff as they exercise on some of the cardiovascularequipment that is available at the Life Design Center.

The Planning and Executive Support Organiza-tion collaborated on a corporate strategic planningprocess that began with a set of global planningassumptions agreed to by the Laboratory LeadershipTeam and Mission Council. These assumptionshelped to establish a new Strategic ManagementUnit structure for FY04. The new SMUs producedextensive 10-year, 5-year, and 1-year corporate plansthat will be housed in the Corporate Plans and Per-formance Assurance (CPPA) database. (12100)

At the request of executive management a studyof “quality of life” issues for administrative man-agers was undertaken. This study, developed by ateam of administrative managers, included a num-ber of focus group sessions and a survey question-naire sent to all administrative managers. The studyidentified four major issues that negatively impactadministrative managers’ quality of life. In responseto these issues, 13 action items were identified andare being pursued by the appropriate individuals orteams. (12100)

An Enterprise Risk Management (ERM) Systemwas begun at Sandia. This ERM system consists ofgoals and principles, process guidance documenta-tion (including addendums that assist risk identifi-cation and provide exemplary case studies of riskmanagement), training, a website, and greatprogress on clarifying roles and responsibilities andimplementing requirements. (12100)

Sandia became an official member of the Santa FeInstitute’s Bus-net, an influential network of 50-pluspublic and private sector entities committed to devel-oping practical applications for the emerging area ofcomplexity science. Recognized as the world leader inthis field, the Santa Fe Institute co-hosted with San-dia a workshop on terrorist behavior that drew arecord number of participants. This was a Labs-widecollaboration involving the Science, Technology andEngineering SMU (funding), the Advanced ConceptsGroup (workshop), and Executive Staff (catalyst andPOC). (12100)

The 2003 Logistics Forklift Safety Rodeo wassuccessful in achieving a Silver President’s Qualityaward. The event, in its third year, showcases theskills and training of Sandia’s forklift operators witha tremendous emphasis on safety and detail. Theevent boosts morale and fosters good customer rela-

tions, creates and maintains networking and part-nering opportunities with other organizations, andpromotes teaming, one of Sandia’s core values.(10200)

The Distributed Information Systems Labora-tory (DISL) achieved a major milestone with thecompletion of building construction in November.DISL will provide the Simulation Enabled ProductRealization (SEPR) program with office and labora-tory space to invent the future of distributed com-puting through computer sciences research anddevelopment. DISL will also stimulate deployment ofSEPR-developed technology to weapons workgroupslocated in classified spaces in DISL. (8500, 8900)

A new Moves Process went into effect at San-dia/New Mexico in January 2003, simplifying whatcustomers have to do to coordinate relocation oftheir phone line, network connection, computer,furniture, and boxes. The new Moves Process linksthe move-related responsibilities of Facilities, Com-puter Support Units (CSUs), and Telecommunica-tions through the use of a software tracking applica-tion that keeps all service providers automaticallyaware of the current status of each planned move.(9300, 9600, 10800)

At a major annual cleaning industry sympo-sium, Sandia’s Custodial Services won twoawards, best custodial audit and the top honor,best overall custodial program. Sandia competedagainst more than a hundred participants fromacross the US, including Boeing, the University ofMassachusetts at Amherst, Sodexho, and the Uni-versity of Texas. Custodial Services has used Oper-ating System One, or OS1®, an innovative andnationally acknowledged large-scale team cleaningsystem, for the past several years to improve effi-ciency and save costs. (10800)

The Corporate Projects Department completedseveral Institutional General Plant Projects(IGPPs) in FY03. These included the new parkinglot on the former site of Bldg. 852, an addition toBldg. 750, and two new buildings — Bldg. 752 inTech Area 1 and Bldg. 969 in Tech Area 4, providing46,000 square feet of much-needed general officespace at Sandia/New Mexico. Thanks to a design/build contracting strategy, each project wasdesigned and built in six to eight months. (10800)

Sandia’s Decontamination and Demolitionprogram removed almost 67,000 square feet ofsubstandard space in FY03, including Bldg. 841,which freed up needed real estate in Tech Area 1. At39,900 square feet, Bldg. 841 is the largest structurethe program has removed to date at the Sandia/NewMexico site, at least until Bldg. 805 (75,300 squarefeet) comes down in FY04. In preparation for thiseffort, the program devoted significant FY03resources to decontaminating Bldg. 805. (10800,10200, 3100)

FY03 inventories of equipment and attractiveassets produced “outstanding” (99.65) and “excel-lent” (99.39) results. With the assistance of Logistics,Procurement, Facilities, Security, and the CIO, lineproperty coordinators located in just six monthsmore than 55,000 assets within the 1,274 govern-ment-owned buildings that total more than 6.272million square feet. FY03 results revealed improvedproperty stewardship over FY99 performance anddemonstrated successful implementation of soundmanagement practices — retaining assurances of sys-tem integrity to Lockheed Martin and DOE/NNSA,while reducing line effort, thereby maximizing con-tractor resources for mission work. (10200)

With filling and covering of the engineered con-tainment cell, the mission for Sandia’s CorrectiveAction Management Unit (CAMU) has been com-pleted. The CAMU, unique in the DOE complex,has been used for the staging, treatment, and con-tainment of hazardous and toxic waste generatedduring soil remediation. The CAMU’s cell containsmore than 31,000 cubic yards of contaminated soilexcavated from the Chemical Waste Landfill. Con-ventional off-site disposal of this material wouldhave expended more than $250 million of taxpayerfunds. (6100, 3100)

Based on results of quarterly inspections andsampling at Sandia monitoring stations, the City ofAlbuquerque awarded Sandia five gold awardsfor compliance with wastewater discharge permits.The Model Validation Design Team won DOE Pollu-tion Prevention (P2) and White House Closing theCircle awards for incorporating sustainability intofacility design/construction. A P2 award wasreceived for a site-wide energy-savings contest.Sandia’s P2 efforts were recognized as models forother large federal and private institutions. (3100)

Emergency Management deployed more than1,350 Tone Alert Radios (TARs) at the New Mexicosite through the SPAN (Sandia Protective ActionNotification) program, enabling the EmergencyOperations Center to communicate time-urgentinformation, protective actions, and instructions toonsite personnel located indoors. TARs can broadcastpre-recorded and impromptu messages by building,groups of buildings, tech area, or Labs-wide. In spe-cial applications, TARs are supplemented with strobelights and text message boxes. Additionally, approxi-mately 125 Building Evacuation Teams were trained,enhancing evacuation procedures and implementa-tion of shelter-in-place actions.

IES — FACILITIES/ADMINISTRATION/LOGISTICS

Center 3100’s waste management departmentsreduced Sandia’s environmental risk by disposingof legacy waste. This included some 60,000 lb. ofexplosive waste consisting of WWII ammunition/gunpowder, ProForce training ammunition, field-test waste, and obsolete rocket motors (approxi-mately 36,000 lb.), as well as emergency explosive

waste (diethyl ether) and routine waste from ongo-ing programs. Additional waste reduction included456 cubic meters of legacy low-level radioactivewaste shipments to Nevada Test Site, whichexceeded the volume of radioactive waste shipmentsto that location in any previous year. (3100)

ENVIRONMENTAL MANAGEMENT

AND REMEDIATION


A CREW prepares to receive another load of contaminated soil at Sandia’s on-site Corrective Action Management Unit(CAMU) facility. The CAMU completed its mission last year.

A FORKLIFT operator lines up a shot during the annualSandia Forklift Safety Rodeo.

Our breakthrough in deep ultraviolet (UV) solid-state, light emittingdiodes (LEDs) has led to continuous optical powers of 1.3 mW at 290 nm and0.5 mW at 275 nm, and peak output power exceeding 8 mW at 290 nm underpulsed operation. These LEDs have been used in demonstrations of bio-agentdetection and a non-line-of-sight communication system. Further develop-ment could enable water purification, decontamination, and thin-film curing.Team members received an award for excellence from DARPA. (1100)

Two-Dimensional Metal: Fact or Fiction? We have studied the physics ofelectrons confined to two dimensions (as seen in silicon transistors) to deter-mine whether this system is a metal or insulator at temperatures near absolute

Sandia played an integral role in helping NASAunderstand the underlying cause of the shuttleColumbia accident. Sandia staff conducted computa-tional analyses and experimental studies to confirmthat foam from the external tank impacted andseverely damaged the wing leading edge on takeoff.More than 35 Sandians contributed to the investiga-tion in the areas of continuum/non-continuum com-putational fluid dynamics, aerothermodynamics,impact analyses, and material characterization. Sandia’ssimulations of the foam impacting the wing leadingedge showed the potential for significant damage, andwere later confirmed by full-scale impact tests. (9100,1800, 6100, 8700, 9700, 15400)

Sandia hosted the 7th National Congress onComputational Mechanics with a record-breakingattendance of 1,200 representing 36 countries. Thecongress featured 62 mini-symposia with 27 parallelsessions each day. Cutting-edge applications andnumerical methods research were represented. Themain objective was to bring together the diverse com-munities in computational mechanics, promotinginteractions between government/academia/industry.The congress was administered by a web-centric data-base that accommodated mini-symposium proposals,abstract submission, registration, and technical pro-gram administration. This tool will be used with futureSandia-sponsored conferences. (9100)

The Test Capabilities Revitalization team completedthe design of the first phase of a $118 million construc-tion line item that will restore critical test capabilitiesand provide new qualification, weapon development,

and model validation capabilities for the 21st century.This $47 million first-phase project will enhance theaerial cable facility mechanical testing capabilities andconstruct a one-of-a-kind thermal test complex to per-form abnormal thermal environment testing ofweapons systems and conduct fire physics R&D. (9100,10800, 1200)

The Joint Test Program completed a multi-yearprocess designed to develop a Salinas finite elementmodel to simulate mechanical shock from hostileencounters. A series of model validation tests culmi-nated with system impulse tests which provided excel-lent data to assess the model utilizing statistical mea-sures of unit-to-unit variability. The data confirmed theconservative quality of the million-element Salinasmodel. The model simulated responses of multiplenon-testable environments, confirming that Sandiacomponents have the capability to survive hostileshocks. (9100, 2100)

ASCI-enabled analysis is supporting W76-1 develop-ment and has significantly impacted the firesetmechanical design. Simulations identified designdeficiencies and subsequent modifications for meet-ing requirements. In combination with analysis, a 22-foot drop test in September provided experimental dis-covery data to reduce modeling uncertainties for theW76-1/Mk4A. Acquired data will also define AF&F(arming, fuzing and firing) component environmentalspecifications for future qualification testing. Thishighly instrumented test successfully met all objectivesunder an aggressive schedule to complete the projectbefore the end of FY03. (9100, 2100)


ELECTRONICS

UV LEDs — Sandia researcher Mary Crawford (top photo) was part of a Sandia team that won a DARPA award for its breakthrough work in ultraviolet LEDs. (Photo by Randy Montoya)

ENGINEERING SCIENCE

PHYSICAL TESTING, like this drop test of a weapon casing,is used in conjunction with supercomputer simulations tomake weapons safer, more secure, and more reliable.

zero. Metallic behavior would mean radical new physics and perhaps even newtechnology. While experiments by other groups over the last two decades haveshown indirect evidence for a metallic state, our experiments and associatedtheory reveal insulating behavior, upholding conventional ideas. There is notrue metallic state. (1100)

With MIT, we have achieved world-record long-wavelength lasing fromquantum cascade lasers (QCLs). We have generated wavelengths as long as141 microns (frequency >2 THz) and record operating temperatures in thisregime (137K pulsed and 93K continuous operation). THz spectroscopy haspotential for rapidly identifying chemical and biological agents and for imag-ing applications. Sandia is one of only three laboratories worldwide that hasdemonstrated the sophisticated compound semiconductor growth required forthese structures. (1100)

image of a sandia computer model/analysis of foam impacting · image of a sandia computer...

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