Welcome once again to Sandia’scompilation of significant contributions

made over the course of the last year. If there isa dominant theme, it is the ever expandingdiversity of important national contributions inmany technical fields and to address manyurgent national needs.

• From the imaging of biological membranesand understanding fundamental life processes,to the development of bacteria microsensorsthat can literally diagnose a patient’s disease

within minutes. • From a joint pro-

ject with the Environ-mental ProtectionAgency to protect thenation’s water sup-plies from chemical orbiological attack, toan in-depth analysisdone for the Depart-ment of Energy onthe possible hazardsposed by liquid nat-ural gas fires whichcould result from ter-

rorist attacks on LNG ship transports.• From development of a new wind turbine

built from newly developed materials, tocarrying out flights of highly instrumented air-craft to study the role of clouds in determiningArctic climates.

• From leading a government and industryforum to create and adopt future standards forsoftware reliability, to the creation of a newmanufacturing process using ultra-short laserpulses (approx 10-15 sec) for precision machin-ing of a wide-variety of materials.

These achievements and the many moredescribed in this report attest to the fact thatSandia is fulfilling its national security missions— including a continuing role to maintain thesafety, reliability, and effectiveness of the USnuclear deterrent forces — against a wider setof threats than ever before.

I believe as you read this report you willagree with me that:

(1) our leading-edge science, engineering,and technology developments are helping toachieve a higher level of security for our nationand the world, and,

(2) this work, in so many fields and againstsuch a diverse menu of challenges, is makingSandia a much more interesting institution.

C. Paul RobinsonPresident and Director

In the first quarter of each calendar year the Lab Newshighlights some of Sandia National Laboratories’ principalachievements of the previous fiscal year. Submissions areselected by the VPs’ offices. Numbers in parentheses at theend of some entries represent the Sandia center (or centers)in which most of the work on a particular accomplishmentwas done. The work is presented here by category. We’vefound over time that this organizational approach is help-ful, but it is important to recognize that such categorization,particularly in a multiprogram, multidisciplinary laboratorysuch as Sandia, is to some extent arbitrary. Much of thework listed in the category “Nuclear Weapons,” for example,could very appropriately have been listed under “Comput-ing,” “Engineering Science,” or any one of a number ofother categories. And the converse is certainly true. Indeed,much of the work done across all the Labs’ technical divi-sions supports Sandia’s fundamental mission-relatednuclear weapons work.

For information about how to contact the researchersinvolved in the work mentioned here, e-mail Lab News staffmember Bill Murphy at wtmurph@sandia.gov.

C. PAUL ROBINSON

To all Sandians:

Sandia National LaboratoriesSandia National Laboratories is a multiprogram laboratory operated bySandia Corporation, a subsidiary of Lockheed Martin Corporation and aprime contractor to the US Department of Energy’s National NuclearSecurity Administration.

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.

Nuclear Weapons . . . . . . . . . . . . . . . .3

Electronics . . . . . . . . . . . . . . . . . . . . .5

Homeland Security . . . . . . . . . . . . . . .6

Biology andNanotechnology . . . . . . . . . . . . . . .7

Engineering Sciences . . . . . . . . . . . . . .7

Energy andInfrastructure Assurance . . . . . . . . .8

Manufacturing . . . . . . . . . . . . . . . . . .8

Nonproliferation . . . . . . . . . . . . . . . .10

Materials, Physics,and Chemistry . . . . . . . . . . . . . . .11

EnvironmentalRemediation . . . . . . . . . . . . . . . . .11

Advanced Concepts Group . . . . . . . .11

Military Technology andApplications . . . . . . . . . . . . . . . . .12

Computing . . . . . . . . . . . . . . . . . . . .13

Pulsed Power . . . . . . . . . . . . . . . . . .14

Security . . . . . . . . . . . . . . . . . . . . . .14

Integrated EnablingServices . . . . . . . . . . . . . . . . . . . . .14

Technology Partnerships . . . . . . . . . .16

Sandia National LaboratoriesPage 2 • Sandia Lab News

Ken Frazier • EditorBill Murphy • Labs Accomplishments coordinator

Table of contents . . .

Photos this page by Randy Montoya

THE W76-1/Mk4A DESIGN DEFINITION continued to maturewith successful reentry body system and Arming, Fuzing, andFiring (AF&F) systemBaseline Design Reviews.The Preliminary WeaponDevelopment Report wascompleted, and the DoDPreliminary DesignReview And AcceptanceGroup independentlyvalidated that the systemdesign and qualificationare on track to meet themilitary’s requirements.Four reentry bodies,including the first fullyfunctional AF&F and newJoint Test Assembly, wereassembled and deliveredto the Navy for flight testing in early FY05. (2100, 1700, 1800,2300, 2500, 2600, 2900, 8200, 9100, 12300)

(Continued on next page)

Last May, the Armando SubCritical Experiment wasperformed at the Nevada Test Site, investigating

possible differences in the impulse response of cast andwrought plutonium. The Pulsed Power Sciences Centerled a multi-institutional team to develop and deploy astate-of-the-art flash radiographic capability: the twin-axis Cygnus accelerators provide four Roentgens a meterfrom a 1-mm-diameter X-ray source at 2.2 million volts,about a factor of 50 greater performance than previouslyavailable at the NTS. The accelerators performed per-fectly, and the resulting radiographic data obtained onArmando are excellent. The dynamic experiment wasconducted within a portable blast containment vessel, sothis unique diagnostic infrastructure may be reusedrepeatedly as needed by the NNSA. (1600)

New tenants of the Joint Computational EngineeringLaboratory (below) began moving in last March. Ulti-

mately, 175 personnel relocated to JCEL. Boasting thelargest switching and routing capability for the Sandiacustomer network, JCEL was also the first to use the newHigh Performance Computing network architecture,including 10-gigabyte trunks and dedicated HPC distrib-ution infrastructure. JCEL houses a vast unclassifiedserver room containing the 407-node Linux computercluster and several other large computer resources sup-ported by Engineering and Sciences High PerformanceComputing team. (9100, 9200, 9300, 9900, 2900)

The construction contract for the MESA Weapons Inte-gration Facility (WIF) has been placed, and constructionhas commenced. The overall project is approximately 50percent complete and project performance is on sched-ule and under budget. The MicroFab and MicroLab facili-ties are on schedule to complete construction in FY05 andbegin operations in FY06. The MESA Institute is Sandia’smicrosystems interface to the US academic community. Ithas established collaborations with more than 30 tar-geted universities, with 50+ students coming to Sandiayearly, creating a pipeline for top new hires. (1900)

The second-generation (PA2) Permafrost digital

weapon controller for the W76-1 has been designed, fab-ricated, and tested. Sandia’s Microelectronics Develop-ment Laboratory fabricates PA2 in its CMOS7 radiation-hardened technology. Additional functionality in thenewer version adds 44 percent more logic gates whileretaining a very demanding low leakage current require-ment. The added complexity and demanding specs werecountered by applying lessons learned and technologyimprovements to achieve unprecedented MDL yieldon a chip of this complexity (1700, 2300, 1100)

The development of novel silicone gel materials andprocessing methods for high-voltage devices solved ahigh-risk weapon refurbishment issue. This technol-ogy allows a dramatic reduction in the size and weight ofa weapon component, while assuring the high reliabilityrequired for weapon performance over a broad tempera-ture range. Because of its exceptional mechanical, adhe-sive, and electrical stability, this gel encapsulant hasbeen chosen as a baseline material for future weaponelectrical designs. (1800, 14100, and 1700)

We designed seven SE3331 data-acquisition systems,which have been used to record the interface data betweenthe aircraft and nuclear weapon for certification of nuclearweapon systems. The SE331, installed in B61 and B83Compatibility Test Units, is an event-driven data-acquisi-tion system that records the electrical events of voltage,current, time, and noise, and stores this information innon-volatile memory. It has been used successfully onthe B-2A and B-52H aircraft to verify compatibility withthe B61, B83, and W80 weapon systems. (2900)

We successfully completed a series of high-fidelityB83 JTA surveillance experiments at the Aerial CableFacility. The experiments required close coordinationand extensive planning among 9100, 2900, the NWSMUoffice, Security, ES&H, Facili-ties, NNSA, BWXT/PX, andthe Sandia Site Office. Theseexperiments were the firsthi-fi experiments autho-rized by SSO to be conductedat Sandia/New Mexico. Rig-orous test planning includedintegration with the lineitem construction process, afacility safety assessment,and detailed supportingsafety calculations usingCTH. (9100, 2900)

The Milestone Reporting Tool is a complex-wide,web-based application that tracks Nuclear WeaponsComplex-wide issues. It was developed for NNSA to aidthe integration, planning, and assessment of the scopeof nuclear weapons program work. Since using this sys-tem, NNSA has reduced the time it takes to conductquarterly reviews from two days to four hours. Recentenhancements enable NNSA to conduct this review via

videoconference, resulting in annual savings of at least$400,000. (5400)

Photometrics and Data Acquisition test capabilitiesfacility in Area 3 houses 26 staff, providing theNuclear Weapons Complex with state-of-the-art pho-tometric and data-acquisition capabilities to sup-port weapons qualification and development, investi-gations, and model validation. Additionally, thefacility provides a venue to develop and deployadvanced quantitative photometric capabilities formeasurements ranging from lab microscale to fieldmacro-scale applications. (9100, 10800)

The MC3600A (shownat left), a nuclear safety-critical component for theW87, successfullyattained First ProductionUnit status in June 2004.The MC3600A is an iner-tial switch that closes andlatches 10 electrical con-tacts after experiencingtwo discrete acceleration-time events. During itsfirst production run inFY04, nine MC3600A

units were certified and accepted by NNSA for use in theW87 system. Center 2600 is the design agent for theMC3600A and Honeywell FM&T Kansas City Plant is theproduction agent. (2600, KCP)

Sandia has developed a unique metrology coursedesigned for managers who work in research anddevelopment activities. The course consists of exam-ples of lessons learned across NNSA and emphasizescritical thinking applied to measurements, as well asdiscipline and innovation. It provides tools to helpmanagers determine the appropriate level of for-mality to use in the collection or analysis of data. Thecourse has been presented to more than 200 staff andmanagers at Sandia, Oak Ridge, Lawrence Livermore,and NNSA. (2500, 3500, 2300).

Size requirements for the MC4300 neutron tube haveled to new concepts for target resistors. Integration ofthe target resistor into the neutron tube target insulatorwith a Low Temperature Co-fired Ceramic, or LTCC,design has the potential to enhance reliability, eliminat-ing the need for a hermetic electrical feedthrough, andreduce part count and assembly complexity compared toconventional or thick film resistors. The concept hasbeen demonstrated in prototype, and the technology isbeing qualified as a viable option for the MC4300 base-line design. (2500, 14100, 14400, 1800, 2900, 6200,6700, FM&T)

Eight product testers were built from scratch withina design-build-deliver cycle of only six months.Significant efficiencies were realized through the use ofcommon hardware and software, and each includes real-time data acquisition and process control. Three of thetesters located at supplier sites have the ability to securelytransmit test data to Sandia. (2500)

The Sandia Weapon Intern Program graduated itssixth class in September 2003 and started the Class of2004. The program aims to promote career develop-

Page 3Labs Accomplishments • March 2005

A MEMS COMPONENT, fabricated with the LIGA process from anewly developed high-strength electroformed nickel alloy, wasdeveloped and extensively characterized for possible use in the stock-pile. The Hurricane Spring component has flexures approximately130 microns thick and 1.3 mm tall, controlled to a dimensional pre-

cision of only a few microns across its ~10 mm width. If chosen asbaseline, this LIGA component will be one of the first MEMS sys-tems deployed in the stockpile. The associated process technologyhas been transferred and demonstrated at the Kansas City Plant,where it will be manufactured. (2600, 8700, Kansas City Plant)

MC3600A

Nuclear weapons

ment at Sandia and to achieve complex-wide excel-lence in weapon engineering through education.Among the participants are 12 Sandians and fourNNSA, two Air Force, one DTRA, and three Kansas CityPlant personnel. The one-year curriculum continuesto evolve to meet the changing needs of the nuclearweapons complex. This year included increasedemphasis in Modeling and Simulation and WeaponsEffects education. (2900, 9700, DoD, NNSA)

The stockpile evaluation program executed the firsthigh-fidelity system level surveillance tests under post-9/11 heightened security measures. FY04 accomplish-ments included a successful B61 flight test at theTonopah Test Range and completion of all preparatorymeasures for FY05 B83 testing at both Tonopah TestRange and the Sandia Aerial Cable Facility. Implement-ing these tests required a tremendous amount of coordi-nation and perseverance by several organizations atSandia as well as Lawrence Livermore National Labora-tory, Pantex, and NNSA. (1900, 2800, 2900, 4100, 4200,8200, 9100, 9700)

On June 30, 2004, the Electronic Systems Center(2300) and Honeywell Federal Manufacturing & Tech-nologies delivered the first fully functional MC4655Warhead Interface Module for the W80-3 Life Exten-sion Program. To fit increased functionality into lessthan half the previous volume, the WIM team workedwith Microsystems Center 1700 and developed thelargest mixed signal (digital and analog) application-spe-cific integrated circuit for a nuclear weapon. The WIMwill be the first weapon subsystem to use a MEMS sys-tem for environmental sensing. (2300, 1700, FM&T)

The first fully functional Crypto Coded Switch(CCS) prototypes were built at Honeywell/FM&T, envi-ronmentally tested at Sandia/New Mexico, and deliveredon-time to support the W80-3 Stockpile Life ExtensionProgram. At the core of CCS is the Sandia Secure Proces-sor, a Sandia-designed Application Specific IntegratedCircuit featuring a novel implementation of a Java-basedmicroprocessor. CCS significantly improves the Per-missive Action Link system by supporting end-to-endencryption, higher code/key security, enhanced com-mands, and a designed-for-manufacture packaging con-cept. (2100, 1700, 12300, 14100, H/FM&T)

A ribbon-cutting ceremony was held last fall to celebratethe completion of Sandia’s new Weapons EvaluationTest Laboratory located at the Pantex plant in Amarillo.The $22 million state-of-the-art facility replaced the 39-year-old laboratory, constructed when some of the earlyweapons were first built. It will house more than $90million worth of testing equipment that will conductsystems-level, non-nuclear tests on nuclear weapons andcomponents. WETL is the only US facility that performs

these types of tests. (1800, 2500, 2900 and 10800)

We developed and deployed a major enhancementto the Classified Image Management System thatcopies all of the unclassified images stored on theUnclassified Image Management System to the CIMSnightly. This enables users of the CIMS to work exclu-sively in the classified environment, which significantlyimproves the usefulness of the classified environment.The Image Management System is one of our most heav-ily used engineering information systems (an average of35,000 documents are downloadedevery month by engineers through-out the Nuclear Weapons Complex).(2900, 9300, 9500)

The latest version of the NuclearWeapons Information Environ-ment Portal was deployed in Sep-tember. The NWie Portal providesthe common user interface to theEngineering Information Systems.Engineering information is now pre-sented in an organized fashion basedon the weapon system. Access to theinformation is based on commonneed-to-know control mechanisms.The NWie portal pulls together the multi-year invest-

ment that has been madein the development,deployment, and opera-tion of Sandia’sclassified EngineeringInformation Systems.(2900, 9500)

Interactive ElectronicProcedures (IEP) is aBWXT Pantex (PX) initia-tive to replace the classi-fied paper procedures cur-rently in use. Since Sandiaand the nuclear designlabs have procedure con-currence responsibility forPX, this posed both con-

nectivity and platform compatibility issues for thecomplex. The Qualification Engineering Release wasrecently released for the on-site qualification of the IEPsat the Pantex Plant. This concluded a multi-year effortby Sandia and nuclear laboratory personnel. (2100)

Center 12300 quality engineers provided QualityAssurance support to the W76-1 Life Extension Pro-gram product-realization teams. Major qualificationmilestones of the W76-1 Arming, Fuzing, and Firing Sys-tem components and testers have been met, qualifica-tion documents released, and reviews completed. Thisproject is an excellent example of the successful imple-mentation of the Technical Business Practices andteaming that is taking place among Sandia, theproduction plants, and commercial suppliers. (12300)

The 12300/2100 Virtual Assessment Facility came on-line in FY04 to surety assessments for new and enduringstockpile systems. The facility provides a 3-D stereoenvironment for running virtual assessments of weaponsystem design, functional-ity, and performance inboth normal and abnormalenvironments. The facilitywill assist in integrating theDesign through AnalysisRealization Team program(DART) and Sandia-devel-oped simulation codes intoweapons programs assess-ment/ assurance activitiesin a classified environment.(12300, 2100)

The identification of component-aging effects, theresulting impact to system performance, and the pre-diction of weapon lifetimes is of increasing importanceto the monitoring of the stockpile. Model Based Per-formance Analysis is providing a predictive capabilityby using modeling and simulation of weapon electricalsystems to act as a bridge between aging effects andsystem performance. In FY04, circuit models weredeveloped for the MC2901 and SA2142 (B61 LifeExtension Program), MC3971-B83 Firing Set andMC3719-W87 Firing Set (Component Surveillance

Program). (12300, 8200)

In FY04 Tonopah Test Rangebecame the first site in the DOEcomplex to meet the physical secu-rity requirements required by thenew NNSA Design Basis Threat(DBT). TTR, with the help of Center4200, completed a new Vulnerabil-ity Assessment, was certified for newhigh-powered weapon systems, andconducted a force-on-force exercise.That exercise resulted in the sitebeing certified to test high-fidelitytest units. TTR completed two high-fidelity tests in FY04 ending a sus-

pension on these test activities that had lasted manymonths. (2900)

To ensure continuing safety of nuclear weaponssystems, the materials of their nuclear safety compo-nents must maintain the characteristics upon whichtheir safety function depends. Materials specialists andnuclear safety engineers studied the W78’s nuclearsafety critical components. Thousands of materialsand material combinations were reviewed. Nopotential materials issues were identified. For eachcomponent, several observations and suggestions weremade to enhance component surveillance. The classi-fied report joins those from W76, W80, and W87studies. (12300, 1800)

Tests and analyses were conducted to evaluate theeffects of lightning on several unique facilities,including critical assembly areas at the Pantex Plant, theWeapons Engineering Tritium Facility at Los Alamos,and maintenance and storage facilities at Air Force bases.The work encompassed a wide range of activities, whichincluded performing a cost/benefit analysis of compet-ing lightning protection approaches, measuring thetransfer impedances of reinforced-concrete structures,and bounding the energies delivered to load impedancesrepresenting electrically sensitive components due toindirect field coupling. (12300, 1600)

An external review panel continued to advise San-dia executive management on the effectiveness of theindependent assessment activities of the Weapon SuretyAssessment Center. The panel consists of knowledgeableexecutives with diverse backgrounds and experience innuclear weapons enterprises and other high-conse-quence operations. The panel provides an in-depthreview of Sandia processes to conduct independentassessments of the Weapons Program in twice-yearlyreviews. The panel’s suggestions are tracked and

Sandia National LaboratoriesPage 4 • Sandia Lab News

Two W80 captive carry flight tests weresuccessfully completed in FY04. In thefirst test, temperatures were measured ona mock warhead in a cruise missilemounted on the wing pylon of a B-52.The second test was a series of multipleflights to measure vibration and acousticenvironments in each of the warhead’sthree deployment configurations. Theinformation will be used to establish orupdate W80 environmental require-ments. Center 8200 designed and builtthe data processing and recording equip-ment, and coordinated the flight tests.

A 4,800-POUND PENETRATOR prototype was accelerated on a sled-track, then launched and suc-cessfully impacted into a megalithic, 25-foot-diameter target at a velocity of thousands of feet persecond. The test significantly advanced our ability to study such designs under well-controlled

and meaningful deceleration environments. Specialty on-board instruments captured the extremeaccelerations and stresses experienced by the penetrator components, thus enabling comparisonswith advanced analytical models. ( 8200, 2100, 9100, 15400, 8700, 2600, 12600, 14100)

THE TECHNICAL BASIS used to characterize the capa-bility and reliability of our nation’s only nuclearearth penetrator improved with the development ofthe B61-11 Type 6C Joint Test Assembly. The newconfiguration allows for cable pull-down testing atSandia’s Aerial Cable Facility. Worst-case impactconditions, predicted using aerodynamic trajectorymodeling and penetration simulations, can beachieved using full-scale testing. The first B61-11 Type6C surveillance test is scheduled for 2005.(2100, 2900, 9100)

TONOPAH TEST RANGE force-on-forceexercise earned new certification.

Nuclear weapons(Continued from preceding page)

(Continued on next page)

responded to by the Weapons Systems Division and theSurety Assessment Center in coordination with the officeof the Executive Vice President. (12100, 12300)

The final report of the Joint Nuclear Surety Studyinitiated by the Air Force to improve the security ofnuclear weapons throughout their lifecycle was reviewedby the major commands for potential implementation.The Tri-lab study team (Sandia, Los Alamos, andLawrence Livermore labs) developed an Integrated Secu-rity Architecture including weapon surety upgrades thatcould be implemented without factory retrofit. A formal

Phase 6.2/6.2A Study,requested by US Air ForceSpace Command, has beenapproved by the NuclearWeapon Council Safety andStanding Committee.(12300, 2100, 4100, 8200)

We conducted variousexperiments with fuel-airexplosives (FAE) to be usedfor security applications. Themajor problems encounteredwere control of the fuel-airratio and mixing of con-stituents. A test series wasperformed to develop a FAEscaling law which allows forfuture development of proto-type components. (12300,2100, 2500)

In response to the increas-ing threat environment, across-disciplinary team devel-oped a concept, known asSAFE, to provide an integratedphysical security/use controlarchitecture to provide enhanced security for nuclearassets. Critical technologies to support implementation ofthe concept were identified and may be developed in thecoming years. (12300, 2100, 8200, 4100, 9700)

Development of a unified general-purpose consti-tutive model for geologic materials was completed.This effort, originated in the late 1990s, experiencedaccelerated development over the last several years. Keyapplications include projectile penetration, analysis ofhard and deeply buried targets, and reservoir mechan-ics. The SANDIA GEOMODEL represents a majoradvancement in the ability to model the complex con-stitutive response of nonlinear rock-like materials.(6100, 9100, 9200)

Two milestones were completed that increase confi-dence in the ability of several computer codes to makepredictions to help qualify new weapon components.The codes, developed by the Advanced Simulation andComputing program, simulate radiation transport andelectromagnetics. They model the electrical and mechan-ical response of components in hostile X-ray environ-ments. A validation process was followed to comparepredictions to experimental data. These codes are cur-rently used to support qualification of the new arming,fuzing, and firing component for the W76-1 and the newneutron generator for the W78. (6700, 1600)

Construction and occupancy of the DistributedInformation Systems Laboratory at Sandia/Californiawere completed in 2004. DISL provides Sandia’s

Simulation Enabled Product Realization (SEPR) programoffice and laboratory space to invent the future of dis-tributed computing through computer sciences researchand development. DISL will also help stimulate thetransformation in engineering through prototyping ofnew technologies by weapons engineering workgroupslocated in classified spaces in DISL. (8500, 8900)

The W87 Life Extension Program rebuild of thestockpile was completed at the Pantex plant in Sep-tember, achieving a major milestone for NNSA, and fin-ishing a production effort that started in 1999. Activi-ties in the last year consisted of resolving warheadproduction issues at Pantex, and solving numerousproblems at the Kansas City Plant to keep shipment ofcomponents in line with the Pantex productionschedule. Most notably in 2004, Sandia processed anumber of body sections/heat shields with MarkQuality processes to assure that there were enough partsto finish the last warheads.

The Monitoring Technologies group completed astudy of the X-ray shielding efficiencies of high-puritytungsten in neutron generator surveillance applications.Results show that box shields of reasonable mass willgreatly reduce X-ray-related errors and will improvemonitor accuracy by an order of magnitude. This hastremendous implications for production and stockpilesurveillance of neutron generators. Monitors incorporat-ing X-ray shield boxes will allow, for the first time, accu-rate comparisons of production/shelf-life and stockpilesurveillance measurements. (2500)

Page 5Labs Accomplishments • March 2005

A new development Joint Test Assembly for the W78 Mark12A Reentry Vehicle was successfully launched from Vanden-berg Air Force Base in September 2004. This new Joint TestAssembly, designated as JTA6, contained an advanced, mod-ular telemetry system that transmitted data indicating satis-factory weapon system functionality and vehicle motion per-formance. The JTA6 is representative of a new a family ofJTAs that will provide improved insight and early warning ofaging and performance-related phenomena in nuclearweapons. (2100, 2900, 8200)

THE MC4759 SILICON RE-ENTRY SENSOR (SiRES) is Sandia’s first microsystems-enabled component being considered for use in the W76-1 nuclear weapon lifetimeextension program. Using MEMS technologies, SiRES is intended for precisely moni-toring the decelerations of a re-entry vehicle. During FY04, Group 1 and Group 2Builds were produced and tested. Major technical breakthroughs included ultra-lowcontact resistance and extreme high-shock survivability. The scale of the SiRES chipis depicted here by its size relative to a standard dictionary entry on weapons.(1700, 1800, 2300, 2600, 9100, 14100, Kansas City Plant) (Photo by Randy Montoya)

Sandia designed, built, and delivered 6-bittime-delay circuits (below) for wideband electroni-cally steerable array antennas. Enabled by radio-frequency MEMS systems, this advance offers sig-nificant noise figure improvement for radarsensors and communication systems, includingMESA SAR. Present activities focus on packagedcircuit reliability in relevant operational environ-ments. (1700, 5700)

We have made breakthroughs in the perfor-mance of light-emitting diodes with wavelengthsless than 300nm, achieving optical powers of2.25mW at 297nm and 1.3mW at 276nm. This hasenabled significant gains in the capability of non-line-of-sight communication systems and bio-agent detectors. Additionally, LEDs with emissionas short as 237nm, the shortest wavelengthreported for this type of device, have beendemonstrated. Deep-UV LEDs may replace lamp-based systems in a number of other applications,including water purification, decontamination,and thin film curing. (1100)

Electronics

Nuclear weapons(Continued from preceding page)

Photo by Brian Webb

The Hound trace explosives detection system wasbroadly fielded last year. The New Mexico National

Guard used the Hound in a warfighting and civil sup-port demonstration for the National Guard AdjutantsGeneral from more than 24 states. The South Texas Spe-cialized Crimes and Narcotics Task Force credited theHound with the quick identification of a majormethamphetamine shipment after a routine traffic stoprevealed concealed powder and liquid. The Task Forcesaid the Hound saved lives. Commercialization effortscontinue. (4100)

As part of our mission to support our NNSA NuclearIncident Response Program and the Department ofHomeland Security, we delivered Turbo-FRMAC, a soft-ware tool that allows first responders and consequencemanagers to quickly and accurately assess actionsrequired during a radiological event (nuclear detona-tion, nuclear power plant accident, dispersal of radiolog-ical materials, etc.). The software distills three volumesand more than 500 pages of guidance into a useful set ofinput panels that are user friendly and intuitive to use.The software provides crisis and consequence managersestimates of the near- and long-term radiological effectsto the surrounding population, as well as guidance ondealing with supporting infrastructure such as drinkingwater, food streams, and personal protection guidancefor the public. (4100)

The DHS-IP funded NISAC Western Gulf Coast Infra-structure Interdependency Analysis Project evaluatedpotential effects of infrastructure disruptions andpropagation of impacts to other regions and infrastruc-tures by analyzing disruptions caused by increasedhomeland security levels, loss of physical capacity in watertransportation system, loss of refining capacity, loss ofcrude oil pipeline capacity, loss of refined petroleumproduct pipeline capacity, regional electric power outage,and regional telecommunications outage. This achieve-ment included close working relationships with the USCoast Guard, oil industry, and Port Authorities. (6200)

We developed a suite of components comprising aminiaturized “front end” necessary for biodetector sys-tems. Samples from an aerosol collector have beenautonomously prepared, processed, and delivered intoa microChemLab biodetector. Microseparator/microimpingers provide aerodynamic particle-focusing,

inertial size-separation, and direct-impingement intoliquid microsamples. Components developed for post-collection sample preparation include particle concen-trators based on dielectrophoresis, microlysers to solubi-lize proteins, solid-phase extraction and size-exclusioncartridges, miniaturized pumps, valves, and specializedpower supplies. Initial results for a breadboard systemindicate successful processing of Bacillus subtilisspores. (8100, 8300, 8700, 9100)

We conducted analyses, staffed deployments andprovided follow-up assessments for “Orange Alert”activities including the Republican National Conven-tion and New Year’s events to support enhanced radio-logical and nuclear defensive deployments. The RNCactivity proved that a well-designed concept of oper-ations is required to ensure a successful deployment.

Most radiation alarms result from naturally occurringradioactive material, such as ceramics and fertilizer, thatcan overwhelm the secondary screening capacity. UsingSandia’s Sensor for Measurement and Analysis ofRadiation Transients (SMART), spectroscopic detectors,and automatic isotope identification algorithms, nearlyall naturally occurring radiation sources can be identi-fied non-invasively. (4100, 5900, 6300, 8100, 12300)

While Livermore, Calif., residents and visitorsenjoyed Fourth of July barbecues, music, and otheractivities, Sandia researchers and members of the Liver-more Police Department tested a complex system ofsensors and other advanced technologies designed tokeep revelers safe from terrorist attacks. The SensorManagement Architecture, developed by the Center forHomeland Security Systems & Development (8100),linked chemical and radiological/nuclear sensors, sur-veillance cameras, and real-time communications toform a rapidly deployable warning and incidentcharacterization tool for first responders. (8100)

A guideline document intended to improve the pre-paredness of airports against chemical and biologicalthreats has been published by the DHS PROACT airportchem/bio facility protection program. The guide targetsnear-term facility enhancements and response strategiesto prevent or mitigate attacks. This document wasdeveloped by Sandia and Lawrence Berkeley labs, com-bining general chem/bio facility defense expertise withdetailed analyses of facility experiments and exercisesconducted in collaboration with San Francisco Interna-tional Airport. Dissemination to airports nationwideis being coordinated through the Transportation Secu-rity Administration. (8100)

Sandia and EPA are teaming to protect the nation’swater supply from chem/bio attacks. DHS-funded workaddresses indoor (e.g. courthouses, airports) and out-door urban air environments. These projects provideguidance for early-warning systems and response plans.Sandia helps sites prepare by assessing risk and comput-ing optimal sensor locations. Real-time physics-basedalgorithms use sensor data to compute optimal strate-gies for protecting people and decontaminatingfacilities. EPA enthusiastically writes, “This is anexcellent opportunity to leverage the analytical andcomputational skills at Sandia. . . .” (9200, 6100)

Sandia National LaboratoriesPage 6 • Sandia Lab News

Homeland Security

DAVE HANNUM demonstrates the drug-sniffing capabilities ofthe Hound handheld sniffing device. (Photo by Randy Montoya)

Hurricane Frances was heading for Florida,expected to hit land in two days. Sandia got

the call to answer difficult, crucial questions beforeFrances struck. What infrastructures would be dam-aged? What were the predicted economic costs?Sandia, along with Los Alamos and Argonne

national labs, is developing extensive modeling andanalysis capabilities to provide comprehensiveanswers to critical infrastructure issues. DOE andDHS have regularly called upon these advancedcapabilities to address terrorism, new threats, andemerging issues. (6200)

We have developed a capability that enablesatomic force microscopy (providing

nanoscale topographic information) to be per-formed simultaneously with fluorescent imagingof specific tagged molecules. With this capabilitywe have acquired the first-ever simultaneoustopographic/fluorescent images of model mem-branes and animal cell membranes (prepared bycollaborators at the University of New MexicoSchool of Medicine). This is a powerful methodthat is expected to lead to new insights into cel-lular processes for both biodefense and healthscience applications. (1100)

Working with a major industrial partner, wehave designed and delivered microsensors to per-form rapid diagnosis of bacterial infections in hos-pital patients. This system eliminates the need fortime-consuming lab tests and expedites treatmentwith appropriate antibiotics. A sample is collectedfrom the patient and introduced to the Sandia-developed sensor, an antibody-coated surface

time for every pixel in the sample’s image. Thisallows us to simultaneously monitor, for the firsttime, the fluctuating spectra and lifetimes of individ-ual fluorescent molecules. By characterizing chemi-cal processes one molecule at a time, this unique toolprovides new approaches for studying fundamentalbiological processes such as antibody binding,enzyme activity, or protein-protein interactions. Sin-gle molecule studies reveal details of such processesthat are obscured in bulk measurements. (8300)

We have discovered a new kind of phase transi-tion at the boundaries between nanoscale gold crys-tals in thin gold films. Atomic resolution electronmicroscopy provided experimental evidence for thistransition, which was confirmed using first-princi-ples calculations to model the electron structure andelasticity calculations to model the bending of goldlattice planes. These results are important becausethey demonstrate that the structure and behavior ofnanoscale boundaries between crystals is very differ-ent from longer boundaries. (8700)

Biology and nanotechnology

The W80-3 Abnormal Environment Verificationand Validation Level 2 Milestone was completed

through the efforts of Centers 8700, 9100, and8900. The team demonstrated a hierarchicalapproach to code verification and model valida-tion through analysis and testing at increasing levelsof geometric complexity and physical phenomena.The project focused on assessing capabilities (withquantified uncertainty) to predict W80-3 responseto abnormal mechanical and thermal environ-ments. The results support the W80-3 qualifica-tion activities.

We used a new thermal-electrical-mechanicalcoupled-physics analysis code to describe the 3-Dmotion of a microsystems thermal actuator. The

actuator could be used in mechanical non-volatilememory devices. This new analysis capability wasdeveloped by coupling thermal, electrical, andmechanical analysis programs within the Sierraframework. This analysis capability can run on theworld’s fastest parallel computers, and will acceler-ate microsystems development rates. This projectincluded analysts and code development teams in9100 and microsystems designers in 1700.

The Analyst Homepage is an online resource formodeling and simulation analysis. It presents awealth of information about codes, tools, servers,and other topics of interest to analysts. Because ofthe sheer volume of information and the unchartednature of the project, it took tremendous effort onthe part of the developers and the project owners,

including user research, information architecture,interface design, coding, and maintenance. The sitehas received more than 25,000 hits per month sinceits deployment. (9500)

DART, the Design Through Analysis RealizationTeam, has set its sights on improving scientific andengineering analysis times by an order of magni-tude. Corporate ownership and careful managementhas produced a progressive technical roadmap andaggressive changes within a portfolio of 14 projects.Strategic integration has been accomplished viaXML metadata files. Critical process knowledgeand information has been captured via a compre-hensive analyst homepage. A common user supportstructure has been adopted to enhance usability andsupportability of the codes. (9200)

Engineering Science

SANDIA’S RECORD-SETTING visualization algorithmswere deployed in 2004 through the open-sourcevisualization tool ParaView. Sandia collaboratedwith external partner Kitware Inc. to deploy theData Analysis and Visualization Dept.’s high-endvisualization algorithms, including the world’sfastest parallel rendering algorithm. These algo-rithms scale from the desktop to leading-edge visu-alization clusters and high-resolution display walls.ParaView was recently used to display and explorethe results of the largest finite element simulationdata set at Sandia (greater than 70 million finite ele-ments). ParaView is downloaded by more than 70people around the world each day. (9200)

acoustic wave device. Bacteria identifi-cation occurs within a few minutes.Prototype systems are being developedby our industrial partner. (1700)

We have developed a laser-scanningconfocal microscope that records theentire fluorescence spectrum and life-

We have developed techniques that useporphyrins, the active component of pho-tosynthetic proteins, to manipulate thestructure of platinum at the nanoscale.Altering the processing conditions leads toan amazing variety of nanostructures andfunctional properties. These materials canbe used in numerous applications; one useof particular interest is for the photocat-alytic production of hydrogen using sun-light. A number of industrial firms haveshown significant interest in this new nano-technology capability. (1100)

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Labs Accomplishments • March 2005 • Page 9Page 8 • Sandia Lab News • Sandia National Laboratories

Energy and infrastructure assurance

The Neutron Generator Production Centeruses Lean/6 Sigma (LSS) methods in its

continuous improvement program. Use of theLSS Vertical Value Stream process allowed theQuality Front End Work-In-Process team to bet-ter organize, prioritize, and manage its projectplan. It resulted in project completion fourmonths ahead of schedule and improved qual-ity of the Oracle Manufacturing Applicationinterface and work-in-process tracking systemthat was implemented for production floor per-sonnel use. Oracle production floor transactionentry efficiency was improved by 75 percent.The team presented its improvements at the2004 Association for Manufacturing ExcellenceConference in Cincinnati. (14400)

The Ceramics and Glass ProcessingDepartment and the Quality Engineering andAssurance Department collaborated to improveand perform Sandia product acceptance. As aresult of the work, the NNSA Sandia Site Officediscontinued its Quality Assurance InspectionProcedure on two WR nuclear weapon activeceramic components. A zero defect rate ofinspected parts and a robust Sandia productacceptance process have established a high Sandia Site Officeconfidence level with active ceramics product submittals.

The US Bureau of Apprenticeship and the New Mexico StateApprenticeship Council have officially certified 14100’sAdvanced Manufacturing Trades Training Program as anapprenticeship program. The National Defense Industrial

Association recently recognized AMTTP for “DefenseManufacturing Excellence.” AMTTP recruits students attendingNew Mexico technical institutions. Students successfully demon-strate technical capabilities in national technical competitions.Representatives of the Labs and Albuquerque TVI designed theAMTTP using skills standards from the National Coalition forAdvanced Manufacturing. (14100)

A NEW MANUFACTURING TECHNOLOGY based on ultrashort pulse laser processing hasbeen developed to directly micromachine energetic materials and films, create embeddedmicrofluidic channels, and fabricate low-loss 3-D optical waveguides and integratedoptics in bulk glass. This enabling technology minimizes the thermal damage duringmachining of metals and permits the creation of novel photonic devices and structuresand the fabrication of integrated microsensing systems. (14100, 1700, 1800, 15000)

Manufacturing

Energy and infrastructure assurance

LIQUEFIED NATURAL GAS (LNG) is being transported by ship to the United States to meet increasingenergy needs. Multiple government agencies requested that Sandia assess the hazard posed by very large(100s of meters in diameter) LNG fires from potential terrorist attacks. Evaluations of wide variations in pre-dictions from previous studies (including comparisons to nuclear detonations), guidance on best methodsfor analysis, and key sources of uncertainty were analyzed. New, unique experiments are being assembledat Sandia to obtain critical data. Likely causes of a fire and explosion at an Algerian LNG facility were alsoidentified. (9100, 6200, 4100, 2500)

TheAtmospheric

RadiationMeasurement-UnmannedAerospaceVehicle programconducted 14scientific flightsover the DOE sites at the North Slope of Alaskaas part of a three-week multi-agency Mixed-PhaseArctic Cloud Experiment. The complex payload,flown on Scaled Composites’ Proteus aircraft, wascontrolled from a distance of 2,400 miles using alow-cost satellite link. More than 60 hours offlight data were collected to investigate arcticwater/ice clouds. The data will help researchers tobetter understand their microphysical propertiesand role in the atmospheric energy budget. (8200)

Oxygen-containing compounds added to fuelare called oxygenates. The potential for oxy-genates to limit soot emissions from diesel engineshas been known for some time. What hasn’t beenknown is whether (or why) someoxygenates are more effective thanothers. Research (in collaborationwith Lawrence Livermore NationalLaboratory) has significantlyadvanced the understanding ofoxygenated fuel combustion, con-clusively demonstrating how molec-ular structure can play an importantrole in determining the soot-reduc-

tion potential of an oxygenate. (8300)

Sandia was selected last March to lead one ofthree new DOE Centers of Excellence forHydrogen. The $25 million Metal Hydride Centerof Excellence includes eight universities, three com-panies, and five other national laboratories. Itfocuses on developing new solid-state reversiblehydrogen storage materials that will meet orexceed the DOE FreedomCAR goals in 2010 and2015. (8700, 8300, 8200, 1800, 6200)

We have developed, in collaboration with AmericanSuperconductor Corp., a new superconducting wire. The newmethod deposits epitaxial films of superconducting ceramics on aflexible nickel-based tape by dip-coating of solution precursors, andenables high deposition speeds of 120 meters/hour. This methodholds promise for low-cost production of superconducting wire forstabilizing power transmission, increasing efficiency of transform-ers, producing lightweight generators, and improving the sensitivity

of commercial Magnetic Resonance Imaging machines. (1800, 1100)

Sandia’s Center for SCADA Security was established to addresssecurity challenges facing the National Critical Infrastructure.Supervisory Control and Data Acquisition, or SCADA, systems man-age electric power, oil and gas, water, and other critical infrastructure.The Center provides R&D, standards development, vulnerabilityassessments, and outreach to government and industry at its facility.CSS is part of DOE’s National SCADA Test Bed program, theDepartment of Homeland Security Control System Security and TestCenter. It leads $16 million in SCADA security research through theDepartment of Homeland Security and the Institute for InformationInfrastructure Protection. (5600, 6200)

We have developed wind turbine blades that use carbon/glass hybrid materials to reduce weight and shed loads caused byturbulence through aeroelastic twist-bend coupling. The first sub-

scale prototypes have been built and will be tested this year. Thenovel concepts were designed using the Sandia-developedNuMAD tool for blade analysis. Early results are promising, andthree blade manufacturers have been selected for a $7 million,three-year, cost-shared collaboration to take these concepts tofull-scale commercial application. (6200)

We developed a software tool that enables rigorous definition ofdrilling fluid pressure requirements and robust well designs for deep-water subsalt settings. The software interpolates across 580 non-linearfinite element analyses in stress-temperature space to constrain bore-hole closure and casing loading for circular and elliptical boreholes.Using experience from WIPP, the Strategic Petroleum Reserve, anddata for deepwater salts, strong, medium, and weak salts are modeled.The software was released to eight oil companies and has beenapplied to several new field developments in the Gulf of Mexico. (6100)

An initiative of the presidents of Sandia and the KurchatovInstitute in Russia to bolster nuclear energy development anddeployment resulted in a joint report signed by seven US national lab-oratories and nine Russian counterpart bodies. The report was agreedon at a US-Russian Lab Directors Forum, held last summer in Vienna.The summary, signed by all 16 research chiefs, asserts: “The time hascome to develop a comprehensive and realistic plan to ensure the

developmentand deploy-ment ofnuclearenergy. Itmust preserveaccess tonuclear energy

sources for all countries of the world, and inparallel, reduce the risks of nuclear arms prolifer-ation, nuclear terrorism, and hazardous impactson environment and population health.”

The Transportation and MaterialsManagement Program completed a structuraland thermal impact analysis of an F-16 crashfor the Nuclear Regulatory Commission. Theanalysis assessed the consequences of an F-16crashing into a cask at a spent nuclear fuel drystorage facility. This work was critical becausethe NRC rejected the initial recommendationthat the probability of an accident was too lowto consider credible. This work includedexpert witness testimony and is critical to the

future licensing of storage facili-ties. This work produced a novelapproach to modeling bolts anda novel application of theSmooth Particle Hydrodynamiccode. (6100, 9100)

Sandia’s CarlsbadPrograms Group, home of thenation’s top experts on WIPP-related science issues, last year applied its expertiseto another thorny waste disposal issue. It com-pleted a Performance Assessment analysis that wasinstrumental in gaining the required EPAapproval to dispose of 20,000 cubicmeters of super-compacted waste producedby the Advanced Mixed Waste TreatmentFacility at the Idaho National Engineeringand Environmental Laboratory. (6800)

Sandia engineers, in cooperation with an internationalcadre of industry partners and the Nuclear RegulatoryCommission, completed and documented a three-yeareffort to define the state-of-the-art in fire probabilisticrisk assessment for the nuclear energy industry. Sandia hasbeen the lead laboratory for regulatory fire safety researchfor three decades. The work is a watershed in cooperativeresearch between nuclear regulators and industry, andenables implementation of an essential goal for the NRC:risk-informed regulation for fire protection at nuclearpower plants. (6800)

As part of our geothermal research programs, we havedeveloped high-temperature electronics and instrumenta-tion. After 7,950 hours at 193°C, a Sandia-developed high-temperature, high-pressure well-loggingtool using a Silicon-On-Insulator chip setis setting new records for long-term wellmonitoring. The Sandia-designed 250°Cchip (manufactured by Honeywell) is theheart of a long-life data-acquisition sys-tem capable of monitoring geothermalwells, advanced fighter aircraft, oreven future Venus explorers. (6200)

Center 6800 led a Sandia team toprovide nuclear reactor andaeroshell design expertise toNASA and its industrial aerospaceteams for a proposed Jupiter IcyMoons Orbiter (JIMO) mission(see NASA illustrations, left andright). This mission will use anuclear reactor to power electricthrusters, enabling a fuel-efficientflight to Jupiter. Moving forward,Sandia will be part of the teamthat will design, develop, and testthe JIMO orbiter for the 2016launch. (6700, 6800, 9100)

Sandia delivered the Ground-Based Nuclear ExplosionMonitoring Knowledge Base Version 6 to the Air Force

(images above). The Knowledge Base was a collaborationamong Sandia, Los Alamos, Lawrence Livermore, andPacific Northwest labs, where Sandia acts as both a con-tributor and as system integrator. The Knowledge Base iscritical in improving the ability of the US to detect,locate, and identify clandestine nuclear tests by providingdetailed knowledge of the earth’s structure, signal prop-agation characteristics, and analysis tools. There are now99 unique products in the Knowledge Base. (5700, 5500)

Sandia has transitioned a new sensor microsystemfrom concept to spaceflight-quality fabrication in only

three years. Thesemicrosystems are basedon custom sensor read-out and signal processingIntegrated Circuits (ICs)designed and built atSandia. Two hundredfifty-six of these ICs areassembled onto two-sided multichip modulesand integrated into amulti-layer assemblywith a photodiode array.We are fabricating thesehighly integrated sensor

microsystems for the next generation of Global Posi-tioning System satellites, and two flight-quality sensorsare complete. (5700, 1700, 1800, 14100)

For applications requiring both data encryption andauthentication, we have developed new algorithmsthat use information from the internal state of a standardcipher to provide data authentication at little more thanthe computational cost of encryption alone. Their“Cipher-State Mode of the Advanced Encryption Stan-dard” is a National Institute of Standards and Technol-ogy (NIST) candidate mode of operation for an authenti-cated encryption standard. This same algorithm wasrecently integrated into a commercial software prod-uct to support Sandia’s Cyber Security of Utility Opera-tions project. (5600)

At the conclusion of a 6-year, $15 million effort, wedelivered a suite of advanced radiological debris col-lection and analysis systems to harvest gas and partic-

ulate samples. The work is part of an Air Force missionto conduct international nuclear test ban treaty moni-toring. The Advanced Atmospheric Research Equip-ment provides significant enhancements in computercontrol and data management, real-time radiationmonitoring, and crew safety radiation monitoring. Lastsummer the equipment was installed on an Air ForceWC-135 (Boeing 707) aircraft and successfully flight-tested. (5500, 5900)

The AURA(Advanced UV Remote-sensing Applications)airborne lidar, a tech-nology developed toperform standoffdetection of WMD pro-liferation “markers,”underwent extensiveflight test evaluations.The system wasinstalled on a Proteusaircraft and completed50 hours of flight test-ing over a period of 11days. Airborne collec-tions were successfullyperformed to validatedesign performanceestimates and betterunderstand the limitsof this technology foroperational applica-tions. (1100, 2300,5700,6100, 8100,8300)

Sandia’s Center forCyber Defenders(CCD) program useshighly qualified stu-dents interested inbecoming cyber secu-rity professionals toaddress cyber security challenges facing the nation. Stu-dents work on research projects and develop securitytechnologies relevant to Sandia’s mission: network visu-alization, supervisory control and data acquisition(SCADA) security simulation, sensor network security,

computer network mapping, and wireless network secu-rity analysis. So far, the program has recruited 52 stu-dents from 22 universities across the country. ThirteenCCD alumni are now Sandians. (5600)

Sandia has delivered the first of the next-generationGlobal Burst Detector (GBD) payload for integrationwith the first Block IIF Global Positioning System (GPS)

spacecraft. The GBDencompasses a suite ofsensors that perform thenuclear event monitor-ing mission of the USNuclear DetonationDetection System. TheGBD sensors aredesigned and producedby Sandia and LosAlamos National Labo-ratory with Sandia alsoresponsible for overallsystem engineering andintegration. (5700)

The RadiologicalThreat Reduction (RTR)Program at Sandiasecured 24 sites withhigh-risk radiologicalsources. In Lithuania,five hospitals and onewaste repository sitereceived securityupgrades and a searchfor orphan sources wasconducted at 39 loca-tions. Sandia is workingwith the Russian Federa-tion Navy to dispose ofRadioiostopic Thermo-electronic Generators(RTGs), replacing themwith alternative energysystems. Also, in prepa-

ration for the 2004 Olympics in Athens, the teamsecured 18 sites and trained Greek officials on safe-guarding radiological materials. (6900)

The Sandia-developed Special Sensor F, or SSF, waslaunched on an Air Force weather satellite in late 2003.During 2004, Sandia completed early-orbit testing andextensive calibration of SSF, and declared it ready foroperational use. The sensor provides laser-threatwarning for its host satellite; it is the first of its class —it not only detects laser illumination, but it also charac-terizes the laser energy (both wavelength and incidentenergy) and provides location of origin. (5700)

The Dynamic Explosive Test Site hosts training,research, development, test and evaluation for nuclearemergency responders, the special operations commu-nity, and other federal agencies. Explosive testing sup-ports units in the field (gauntlet test). Lifelike replicas ofimprovised explosive, nuclear, or radiological devices setin realistic training venues (e.g. the Rubik Maru) providechallenges for responders’ tools, tactics, and procedures.Lessons learned during training guide development ofnew tools and techniques, which are immediately put touse around the world. (5900)

The Megaports team successfully developed andinstalled an integrated information technology and com-munications system for use by Dutch Customs in the

Nonproliferation and assessments

IN OCTOBER, the twenty-third Defense Support Program satel-lite (DSP-23) passed its final inspection prior to being shippedto its launch site. This launch will be the last for a DSP satellite,which has been a major element of the US Nuclear DetonationDetection Systems for more than 30 years and a major activityin the Monitoring Systems and Technology Center. (5700)

(Continued on next page)

Sandia National LaboratoriesPage 10 • Sandia Lab News

REALISTIC TRAINING VENUES, like the Rubik Maru platform at the Dynamic Explosive Test Site (above), enable responders toexercise and hone the skills and tactics they need to deal with real-world terror threats.

We have developed a simple and robust generalsensor platform for chemical and biological

detection based on self-assembled nanoporous materi-als. This sensing device is easy to fabricate and can beintegrated with Sandia’s advanced microsystems. Thespecific and selective binding of biomolecules is trans-lated into electronic signals without requiring the com-plicated labeling steps used in the preparation of mostother electrochemical sensors. This ultra-sensitive sensorenables the detection of protein and sequencespecific DNA at the femtomole (10-15 mole) level. (1800)

Metal hydrides are used to store hydrogen and itsisotopes in neutron generator targets. The presence oftritium in hydride systems results in a time-dependentchange of the target material due to the radioactivedecay of tritium to helium-3, resulting in a potentialnegative impact. The behavior of radiogenically pro-duced helium-3 in metal tritide films has been an active

area of interest for more than thirty years but remains apoorly understood phenomenon. Recent experimentsusing several neutron scattering techniques have beenapplied to this problem resulting in first-time observa-tions of helium ordering within an erbium tritidematrix. Studies are under way to determine theunderlying reasons for these observations. (14400)

We have developed a revolutionary new method forcomprehensive 3-D chemical analysis that requires noa priori knowledge of the chemistry. This method pro-vides detailed characterization of critical materials, suchas aging stockpile materials. The X-ray spectral images,analyzed with Sandia’s patented and award-winningAutomated eXpert Spectral Image Analysis software,reveal rich detail not previously available. This infor-mation has been essential for resolving materials prob-lems, such as identifying causes of component corrosionand ways of mitigating future problems. (1800)

Materials, chemistry, and physics

leading international Port of Rotterdam, one of the busiest container terminals in theworld, to deter, detect, and interdict illicit trafficking in special nuclear materials. Systemdesign, installation, and operation included radiation portal monitors, video cameras, andspecial scan trigger sensors. The system is widely recognized and praised for outstandingperformance and attracts port representatives from around the world. (6900)

The Enhanced Radiometer (ENRAD) was launched from Cape Canaveral onJune 23, 2004, on board the GPS Mission IIR-12 satellite. ENRAD is a demonstration of

the next generation of optical sensors whichwill be included on future GPS satellites. Thesesensors will provide significantly enhancedoptical sensor performance for worldwidenuclear treaty monitoring. During the early-orbit test period a series of tests were performedto verify functionality and set operating modesand the sensor was tested with ground-basedoptical pulses. (5700, 5500, 1700, 14100)

Focusing on local infrastructure rebuilding,international R&D, and business development, aninitial survey was made to contact and engagemembers of the Iraq science and technologycommunity. Proposals were requested from Iraqiscientists, and two projects were funded in thehigh-priority areas of water and public health.Current efforts include working with Iraqi scien-tists to develop detailed project proposals that canbe submitted to international funding organiza-tions. This program has strong Iraqi participationand the participation of scientists from other Arabcountries. (6900)

The Advanced Concepts Group has developed a process — called “fests” —for large group brainstorming. Fests are particularly effective in bringingtogether diverse groups to address open-ended questions requiring newapproaches. Two successful Fests were held in FY04 dealing with internationalapproaches for countering terrorism: PACFest involving Singapore, Australia,Guam, Fiji, and Palau in the Pacific region; and NorthAm Fest involvingCanada, Mexico, and the US. (16000)

The ACG developed a strategic architecture for understanding andanticipating terrorist threats toenable a full range of actions forcountering terrorism. An ACG-fundedLDRD for “The Hypothesizer” has cre-ated a prototypical, AI-based tool thatgenerates terrorist scenarios. Thosescenarios, in turn, provide the datathis architecture needs for a betterunderstanding of the full range ofhypothetical terrorist actions. This hasled to a fledgling program in theInformation Systems Center (5500) inKnowledge, Discovery, and Dissemination with the intelligencecommunity. (16000)

An understanding of terrorist motivation and intent will greatly improveour ability to anticipate terrorist targets and methods, disrupt their opera-tions, and narrow the field for homeland defense. The ACG developed a pro-gram for this purpose, including the establishment of Knownet, a network ofterrorism experts now available to the homeland security and intelligencecommunities. ACG concepts have been adopted by the DHS and incorpo-rated into a new Center 5900 program for that agency. (16000)

Advanced concepts group

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The disassembly/sanitizationprocess for material that wasexhumed during remediationof the Classified Waste Land-fill was completed last Septem-ber. The activity started in Feb-ruary 2000, with no disposalpath available for mixed classi-fied components and no otherfacility available to performthis work. Therefore, the mate-rial was sorted and disassem-bled on-site, involving combi-nations of cutting, shredding,and melting. Approximately30,000 classified items wereexcavated. A few items couldnot be disassembled becauseof ES&H concerns and were managed as classifiedlow-level waste. Approximately 90 percent of the

original volume of materials wasrecycled. (6100, 6300)

Facilities, Procurement, and Pollu-tion Prevention (P2) staff implementedcomprehensive recycling and greenpurchasing programs for construction.Major projects recycle over 80 percentof construction waste, and 99 percentof their purchases meet the EPA’s recy-cled content requirements. Sandiareceived a White House Closing theCircle and NNSA P2 award for greenpurchasing. For construction recycling,Sandia received an NNSA P2 Award,the EPA Waste Wise Program Cham-pion Award for the Federal Govern-ment, and the New Mexico Recycling

Coalition “Federal Facility Recycling Program of theYear” award. (6300)

Environmental remediation

Nonproliferation(Continued from preceding page)

COMPREHENSIVE 3D chemical analysis of localized corrosionon a gold- and nickel-plated copper substrate. The gold layeris red, copper substrate is green, unexpected silicon oxidecontaminant is blue, copper sulfide corrosion product is cyan

(light blue), and nickel layer is yellow. The silicon oxidecaused a hole in the nickel and gold layers which resulted incorrosion after atmospheric exposure.

Page 11Labs Accomplishments • March 2005

ENRAD launch at Cape Canaveral.

Sandia designed, produced, and tested shoulder-lengthgauntlets to help protect the arms and lives of mili-

tary personnel in combat. The gauntlets, forearm andupper arm protective inserts as seen at right, made ofKevlar layers with carbon-composite, protect soldiersriding atop military vehicles from Improvised ExplosiveDevices (IEDs). Army representatives are collectingstatements from troops who have worn the gauntlets.Among the comments: “They really like the gauntletsand think they are a great item;” “impressed with thegauntlets;”, and “looking forward to receiving manymore gauntlets.” (6900, 15300)

Exoskeletons for soldiers require advanced sensingof their environment, including ground reaction forces

and terrain sensing. Tosolve this problem, aSandia team (15200,1700, 14100, and 9100)produced a customMEMS-based pressuresensor array and inte-grated it into anexoskeletal boot sole.The team advanced thestate-of-the-art inmicrosystems deploy-ment by packaging a del-icate MEMS device towithstand the abusiveenvironment encoun-tered by the bottom of asoldier’s boot. (15200)

The US military needsa rapid-response, preci-sion-strike conven-tional weapon capableof holding hardened anddeeply buried targets at

risk. The Tactical Missile System Penetrator project isan Advanced Concept Technology Demonstration todesign, develop and demonstrate such a weapon system.The US Navy Strategic Systems Programs Office issponsoring Sandia’s work in this conventional warheadpayload effort. The project is in the flight demonstrationphase. An FY05 project deliverable will be six combat-capable residual assets. (1800, 2300, 2500, 2600, 2900,3100, 9100, 10200, 12300, 14100, 15400)

The Intelligent Systems Controls Department(15234) has recently developed aWheeled Hopping Vehicle (photo atright) for DARPA’s Advanced Tech-nology Office. This man-packablerobot vehicle uses a combustiblecylinder to jump over 8-foot-tallobstacles. This capability allows asmall vehicle to negotiate roughterrain previously considered impos-sible. Applications for this robot vehi-cle include searching caves and deeplyburied facilities. (15200)

The Targets Program delivered two target pay-loads to support Missile Defense Agency launches inearly FY05. These launches test the effectiveness ofour nation’s missile defense system. Five additionaltarget payloads reached various stages of completionin FY04, all of which will support flight tests in FY05.The newest of these payloads, designed by Sandia inFY04, involves highly advanced developmentwork, including Wireless LAN technology. Thisadvanced development work aligns with our pro-

gram’s future objectives as well asthe Labs’ vision. (15400)

The Penetration Science and Tech-nology Department and the StructuralMechanical Engineering Departmentdesigned and successfully demon-strated a new, two-piece penetratorwith a jointed-nose that provides thefollowing advantages: Precision deep-cavity machining of high-strengthsteel alloys; uniform heat-treatment;expanded assembly options; forwardfuze placement; nose-shape; nose-material optimization; and reducedproduction costs. The elements ofthese designs have been used acrossthe Lab, and are being embraced byDoD laboratories and contractors.

We are developing the technologyfor an eye-safe, robust, low-cost,lightweight, 3-D structured light-ing sensor for use in broad daylightoutdoor applications. Structuredlighting requires image processing toisolate or segment a laser signal frombackground clutter in a cameraimage, which is difficult to accom-plish under bright outdoor condi-tions and with highly absorptive sur-faces. Applications include precision mapping,autonomous navigation, dexterous manipulation, sur-veillance and reconnaissance, part inspection, geomet-ric modeling, laser-based 3-D volumetric imaging,simultaneous localization and mapping (SLAM), aid-ing first responders, and supporting soldiers with hel-met-mounted LADAR for 3-D mapping in urban-environment scenarios. (15200)

Sandia staff are helping the US Navy create next-generation aircraft carrier operations by conductinganalyses leading to improved performance, reducedmanpower, and reduced costs. After successful comple-tion of a four-month evaluation of current Navy airwing operations, structure, and preliminary improve-ment alternatives in FY04, a strategic partnership hasbeen formed through at least FY07 to develop a “sys-tem of systems” analysis capability providing greaterquantitative understanding of the aircraft carrier sys-

tem to improve decision-making regardingorganizational structure and resource

allocation. (6800, 6200, 15200)

The Micro Analytical SystemsDepartment is completing work forthe Defense Emergency ResponseFund to address mass-manufactur-

ing and other critical issues forMicroChemLab. DoD had significant

reproducibility problems with produc-tion of other chemical sensor packages.

We have overcome many of theseissues and have developed apparatus to repro-

ducibly deposit polymer films and sol gels for ourchemical analysis system components. In addition, wehave established commercial manufacturers for eachof the critical components for MicroChemLab. (1700)

Significant new electromagnetic launch capabilityhas been achieved this year as a result of new launchprograms supported by DoD and Lockheed Martin. Aprogram has been initiated by the Defense AdvancedProjects Agency to analyze and demonstrate EM launch

capability for mortar-class artillery. The goal of thisprogram is demonstration of full-scale launchers (bothrailgun and coilgun variants) at muzzle velocity of420 m/s for 120 mm mortar projectiles, with kineticenergy of 1.6 MJ. The EM Mortar team is composed ofthe following organizations: Sandia (lead), Institute forAdvanced Technology (IAT) at the University of Texas;The Army Research and Development Command,Picatinny Arsenal; the National High Magnetic FieldLaboratory at Florida State University and Los AlamosNational Laboratory; and TPL, Inc. (15300)

A full-size EM launcher for vertical launch missilesystems has been demonstrated at Sandia through aShared Vision program with Lockheed Martin MarineSystems and Sensors Division in Baltimore. Our missilelauncher demonstration test-stand has been assembledand tested with full mass (1430 pounds) and velocity of10 m/s, the velocity predicted for the five-stagelauncher. The payload is launched to a height of morethan 20 feet, as predicted from launcher simulation.This revolutionary launch capability is being pre-sented to the Navy Sea Systems Command and Office ofNaval Research in a series of briefings and demonstra-tion launches. (15300)

Military technology and applications

AS PART OF the Enhanced PerceptionLDRD, we’re developing robotic vehi-cles capable of autonomously gener-ating maps. The map at left was gen-erated from a laser scanner mountedon a mobile robot. The robot usesthese maps to plan its own paths. Therobot continuously correlates itsscanned data to the map to localizeitself as it navigates. Data fromupward-looking sensors are stitchedtogether to generate 3-D maps. 3-Dmaps provide enhanced situationalawareness to the operator.

MEMBERS of the New Mexico Army National Guard demonstrate how Sandia-devel-oped Kevlar gauntlets would be deployed in the field. (Photo by Randy Montoya)

JOHN JOJOLA (15335) prepares the electromagnetic missilelauncher for a test flight. (Photo by Randy Montoya)

Sandia National LaboratoriesPage 12 • Sandia Lab News

Sandia chaired the Society of Automotive Engineers’Software Committee that published six software reli-

ability and supportability standards and guides that sub-sequently were adopted by national security organiza-tions including the US Army and NATO, and industriesincluding Boeing and Lockheed Martin. The lessonslearned from major software-intensive programs such asthe Eurofighter were incorporated. These publicationsprovide a comprehensive approach to addressing theconcepts, strategy, processes, and implementation of asoftware supportability program and software reliabilityprogram within a systems context. (12300)

A Presidential Early Career Award for Scientists andEngineers was presented to Tammy Kolda (8900), inSeptember 2004. The award is “the nation’s highesthonor for professionals at the outset of their researchcareers,” according to the White House Office of Scienceand Technology Policy. Tammy was nominated bySandia and DOE’s Office of Science for her innovativeresearch in algorithms and software for optimization,parallel computing, and nonlinear solvers. Tammy is thethird Sandian to receive the award since its inceptionin 1996. (8900)

Strategic Web Infrastructure Framework & Technolo-gies (SWIFT) used portal technology with Sandia’sexisting infrastructure to improve the content, presenta-tion, and usability of Techweb, Sandia’s internal web-site. Techweb gives Sandians better access to the infor-mation they need. Portal technology allows SWIFT tobuild flexibility into information delivery, avoid userinformation overload by allowing users to customizetheir Techweb site, distribute maintenance of corporateinformation, offer a single point of access to multipledata resources around the labs, and facilitate onlinecommunities of interest. Many groups contributed,including Corporate Communications, CEDT, Infra-structure, IES, Oracle Financials, PeopleSoft HRIS, San-dia/California, and the Technical Library.

Sandia Anywhere collects into one place(http://anywhere.sandia.gov) the established methodsfor remote access to resources on Sandia’s internal net-work, and adds a new production capability — “RemoteDesktop.” After authentication through SecurID, RemoteDesktop allows a user (from any Internet-connectedcomputer) to establish a secure desktop connection tothe Restricted Network. Users can also connect to theirown desktop computers to access data or run programsas if they were sitting in their office. (9300, 9600)

Three buildings were completed in FY04 that pro-vide modern office, laboratory, and computer room

space to support high-performance computing pro-grams. These buildings included the Joint Computa-tional Engineering Laboratory in Albuquerque andthe Distributed Information and Simulation Labora-tory in California. Construction of the SuperComput-ing Annex to house the Red Storm supercomputer wasalso completed. (9900)

On July 13, 2004, Sandia placed a $9.8 million con-tract with Hewlett-Packard to purchase three produc-tion-capacity computing clusters for the Nuclear

Weapons program. These clusters, built on processorsbased on Intel’s Extended Memory 64-bit Technology(EM64T) and Myrinet 2000 interconnect, provide Sandiawith 16 teraops of computing resources. Delivery wasspeedy: Spirit, the New Mexico restricted network clus-ter, was in production, as planned, by November 16.Justice, the New Mexico classified network cluster, andLassen, the California classified network cluster, werereleased to users the following month. (9300)

Sandia was a major participant in the NNSA Inte-grated Cyber Security Initiative, which designed andpurchased the security infrastructure for a classifiedNNSA Enterprise Secure Network. This network willenhance the ability of sites to securely and conve-niently share data across the NNSA in a web environ-ment. Requirements were gathered from all labs andplants and consolidated into an NNSA-wide competi-tive procurement handled through Kansas City. The

purchased hardware and software will be deployed inFY05-06. (9300, 9500)

The Information Management policies were updatedto improve usability and to identify and initiate devel-opment of needed requirements arising from new tech-nology and new drivers. The redevelopment included aself-assessment of existing policy, added sections onnew capabilities and processes, updated terminologyand definitions, and improved search capabilities. Atopical structure, with an associated application, wascreated to make it easier for users to find the require-ments. The Corporate Process Requirement pages werereduced by 30 percent, and the number of policy docu-ments dramatically reduced. (9600, 9300, 9500, 8900,4200, 10700)

The e-mail team in Center 9300, with support fromCenter 9600, completed the migration of all (13,000-plus) Sandia electronic mailboxes to MicrosoftExchange 2003 with increased mailbox size. Macin-tosh users now have access to their mailboxes with afull-featured client (Entourage), giving them suchcapabilities as shared calendaring with co-workers. Inaddition, the new Exchange servers give Blackberrywireless users remote connectivity to their Sandiae-mail. (9300, 9600)

The Enterprise Data Warehouse has grown toinclude 13 data sources used by customers across theLabs. Oracle Manufacturing, Stockpile UnsatisfactoryReports, legacy databases from Pinellas for neutron gen-erator components, underground test data, the NNSAWeapon Information System, the Product Test System,neutron generator components, the weapon Record OfAssembly, and Engineering Bill of Materials are examplesof warehoused information available to the weaponsprogram. In addition, the warehouse effort supportsOracle Financials, satellite data, facility data, and corpo-rate HR data. (9500)

Three computer programs mark major progressby 9200 staff developing agile microsystems designtools and high-fidelity process simulators. Two codesprovide a breakthrough, automated design loop forMEMS (made using standard microelectronics mask-ing and deposition techniques). The unique programFAETHM generates a mask set from a 3-D part design.SummitView, given a mask set, now renders a 3-Dpart 100 times faster than previously. ChISELS, a 3-Dmassively parallel code, accurately models keymicrosystem fabrication processes such as plasma-enhanced chemical vapor deposition and deep reac-tive ion etching. (9200)

Computing

TheTrilinos framework formathematical softwarecontinues to attract interna-tional accolades. The code washonored with an R&D100 Award thisyear, as well as winning the High Perfor-mance Computing Software Challenge.Trilinos (all three images, this page) facilitatesthe design, development, integration, and ongo-ing support of mathematical software libraries formodeling and simulation applications. The code is usedworldwide for large-scale, parallel scientific and engineer-ing simulations, and continues Sandia’s tradition of leader-ship in high-performance computing and software. (9200)

Page 13Labs Accomplishments • March 2005

ASupplier Showcase sponsored by Sandia and the Cityof Albuquerque was held last year. Sixty-five

suppliers in the areas of homeland security, optics, andbiotechnology met with buyers and technical personnelfrom around the state and the region. Following on thesuccess of the 2004 event, the 2005 Showcase will focuson homeland security, manufacturing, and vital resourcessuch as water and environmental quality. (10200)

The Sandia Project Management Portal consolidatesproject management resources into a central locationand provides information on PM events and require-ments. The Project Management Users Group will serveas a community of practice for PM at the Labs. It also pro-vides the opportunity for the Sandia PM community toprovide feedback into future PM efforts, including thenewly established Project Management Resource Office.Phase 2 of the PM Portal will include a PM repository, col-laboration zone, and resource feedback methods. (10500)

In FY04, Sandia received a $2 million New Mexicogross receipts tax refund for FY2000. We will be filingrefunds for approximately $7 million for 2001-2003.These deductions reduce our liability going forward andbring our effective tax rate from an average of 3.2 per-cent to 2.86 percent. This translates to an additionalsavings of $4.6 million for 2003 and $9 million for 2004.As a side note, Sandia is the largest payer of grossreceipts taxes in the state of New Mexico, with morethan $60 million paid in FY2004. (10500)

The upgrade to the latest version of the Oracle appli-cations (Finance, Manufacturing, and Procurement)positions Sandia to provide new capability for moreagile and effective business operations in meeting thedaily business needs of the Labs. The upgrade will enable

better planning for future business needs. BusinessIntelligence (real-time access to information) providesfor more effective business decisions. Enhanced pro-ject management capabilities will increase customersatisfaction, productivity, and allow for easier cost,schedule, and performance monitoring. Self-serviceapplications provide ease-of-use for common businessfunctions.

The Supplier Community Advisory Council, an organi-zation of local business community members, businessdevelopment organizations, and Sandians, recommendedestablishment of the C. Paul Robinson Awards. Theseawards acknowledge Sandia’s project and program pro-curement managers and teams who excel in using regionalsuppliers or who demonstrate excellence in communitydevelopment through procurement opportunities. Dr.Robinson presented these awards at the 1st Annual C. PaulRobinson Awards Ceremony held in February 2004, inconjunction with the Supplier Showcase. (10200)

Sandia’s construction program set a record pace inFY2004, with a budget of more than $230 million.Among the projects under design or construction werethe Microsystems and Engineering Sciences Applica-tions (MESA) Complex, the Weapons Evaluation TestLaboratory (WETL), the Joint Computational Engineer-ing Laboratory (JCEL), the Center for Integrated Nano-technologies (CINT) Core Facility, the Exterior Commu-nications Infrastructure Modernization (ECIM) project,Phase 1 of the Test Capabilities Revitalization (TCR)project, the Heating System Modernization (HSM) pro-ject, and several smaller new buildings and renovationsaround the site.

Sandia became the first and only laboratory in theDOE Complex to have acertified Earned ValueManagement System.EVMS is a tool for mea-suring performance onconstruction projects.Bruce Carnes, NNSAAssociate Deputy Secre-tary, formally certifiedSandia’s EVMS in a letterstating, “The Depart-ment of Energy . . . con-gratulates Sandia Corpo-ration Lockheed Martin

on its acceptance. You have achieved a significantmilestone by demonstrating a performance measure-ment system that provides valid data and is effective inmanaging project performance.”

IES funded two additional Institutional GeneralPlant Projects and vacated 11,000 sq. ft. of Area 1 spacefor mission organizations. IES also began operating theinstitutional cluster computer and 35 terabytes of diskspace funded in FY03 and invested in a second cluster forFY05. A new internal homepage, an accelerated clearanceprocess, and cost estimating tools were introduced. TheIES expanded the disease management program,resulting in decreased health care costs and sicknessabsence, reduced the cost of small facilities projects by50-70 percent, and streamlined the WFO process.

The Materials Management Workshop is an annualmeeting of the Materials Management Association toexchange ideas, address common supply chain problems,and improve materials management in the DOE/NNSAcomplex. The 2004 event was sponsored by Sandia Logis-tics’ Material Movement. Thirty-six members from 13

Z-pinch implosions on the Sandia Z machine havebeen photographed for the first time using bent-

crystal radiography diagnostics. The crystals screenout most of the ~1 million joules of X-rays produced bythe pinch implosion, allowing high-resolution radi-ographs to be made using <1 joules of X-rays from San-dia’s Z-Beamlet laser. The photos provide quantitativeinformation about the initial formation and implosionof the z-pinch plasmas thatwill help researchers opti-mize future designs andimprove X-ray yields. (1600)

Quantum moleculardynamics simulations basedon density functional theoryhave been used to generate anaccurate wide-range electricalconductivity model and man-ifestly consistent equation-of-state for stainless steel inthe difficult warm dense mat-ter regime. Optical conduc-tivities are calculated for sam-pled atomic configurations.These new QMD-basedphysics models permitunprecedented high-fidelitysimulations of high energydensity physics experiments with advanced modelingcodes, such as ALEGRA. (1600)

In the field of complex radiation-hydrodynamics,“rad-hydro,” the Z accelerator has recently extendedits application to yet another area of high energy den-sity physics and inertial confinement fusion. Specifically,in conjunction with the Z-Beamlet laser as the radiogra-phy diagnostic, Z has generated indirectly driven “jets”

that, in addition to being of interest to basic science, mayprovide critical experimental data for benchmarkingcertain weapons science rad-hydro codes. The project is aclose collaboration among Los Alamos, AWE UK,Lawrence Livermore, and Sandia. (1600)

A Z-Pinch Inertial Fusion Energy (IFE) program wasinitiated by Congress to extend the single-shot z-pinch

fusion target results on Z toa repetitive-shot z-pinchfusion power plant conceptfor the economical produc-tion of electricity. Initialresults on recyclable transmis-sion lines, repetitive lineartransformer drivers, thick-liq-uid wall shock mitigation,proof-of-principle experimentplanning, IFE high-yield tar-gets, and z-pinch IFE powerplant technologies supportdevelopment of long-rangeZ-Pinch IFE program. (1600)

Experiments on Z pro-duced a world-record peakvelocity of 34 km/s for amagnetically accelerated alu-minum flyer plate, which is a

factor of four larger than is possible by conventional gasgun techniques. Shots were designed using theALEGRA-HEDP magnetohydrodynamics code combinedwith circuit simulations to accelerate the 0.085 cm thickflyer without shock formation, which destroys it.Velocity measurements proved the flyer was acceler-ated without shock formation, which enabled accu-rate, state-of-the-art, equation-of-state data to beobtained for quartz and sapphire. (1600)

Pulsed power

The Nuclear Safeguards and Security Center has com-pleted testing and evaluation of new perimeter vehicle

barriers that can defeat threat vehicle energies of up to65,000 lbs at 50 mph. Sandia worked with two commer-cial firms, Kontek and RSA Protective Technologies, todevelop the designs. The RSA barrier, tested at the TexasTransportation Institute, stopped the threat vehicle withintwo feet. Computer models of barrier designs also weredeveloped for validation. These new vehicle perimeter bar-riers provide Federal agencies with options to enhance sitesecurity and already are being installed at two DOE sitesand several NRC facilities. (4100)

We recently completed the installation of the first exteriorRemotely Operated Weapon System (ROWS) applica-tion. The weapon platforms (photo below) are installedat a DoD site and safety and operational reviews are

nearly completed. This technology provides near-imme-diate small arms response to potential security threatsand has potential to significantly improve securityresponse effectiveness. Other applications for weaponplatforms are planned at both another DoD site and aDOE facility in FY05. (4100, 5600)

The 2003 Security Standdown resulted in many well-received security initiatives. The Standdown involvedevery member of the workforce and was planned by amulti-organizational team. Approximately 11,500 individ-uals received at least 16 hours of security and awarenesstraining. All divisions prepared a consolidated Stand-down report containing recommendations and com-ments. Data from those reports were analyzed usingdata-mining software, resulting in a corporate report con-taining recommendations. As a result, we implementeda Security Awareness Campaign, Security Help Desk,and the Security Education, Awareness, and LessonsLearned (SEALL) team. (4200)

Over the past several years, various internal and externalaudits identified a number of concerns related to security.Beginning in 2003 and continuing in 2004, these prob-lems within Sandia’s Safeguards & Security (S&S) Programreceived significant senior management attention result-ing in substantial improvement in the S&S Program.NNSA Performance Evaluation Review Ratings for San-dia/New Mexico improved dramatically in 2004, with thehighest rating of satisfactory for 4 of 5 topical rating areas,marginal for one area, and several areas of excellencespecifically identified. (4200)

During the Security Standdown of November 2003, inter-nal customers voiced a loud and clear message that theywanted to do the right thing when it came to security butthat the information presented via the CPR format was toodifficult to locate and understand. Security and technicalcommunications personnel in Center 8500 teamed withline organizations to produce a web-based product withsearch capabilities. This product offers easy-to-findanswers to the most complex questions associated withsecurity requirements.

Security

IES: Integrated Enabling Services

SANDIA’S Decontamination and Demoli-tion program (see photo at left) demol-ished almost 100,000 square feet of spacein FY04. The removal of the 75,300-square-foot Bldg. 805 constituted the lion’s shareof this work and is the largest structure theprogram has removed to date at the San-dia/New Mexico site. This proactive D&Deffort is helping Sandia to comply with thenew congressional mandate to offset allnew square footage by the removal of anequivalent amount of space.

(Continued on next page)

Sandia National LaboratoriesPage 14 • Sandia Lab News

DOE facilities attended. Accomplishments included aquality educational forum, an 80 percent increase inmembership, online registration, national website, devel-oping legacy practices, showcasing Logistics best prac-tices, and partnering with DOE/NNSA, the business com-munity, and nonprofit organizations. This event won a2004 PQA Gold Award. (10200)

Indirect Financial Management developed out-yearinformation to assist the line in forecasting, estimating,and preparing proposals that extend several years out.This Forward Pricing Information consists of forwardpricing rates and standard labor rates. Having this infor-mation available to our line customers helps eliminatesome of the speculation involved when preparing bud-gets and proposals for out years. An added benefit isthat it helped to increase the line’s understanding ofthe Labs’ rate structure. (10500)

More than 23 new technical courses were imple-mented to support the Strategic Education Plan initia-tive. This Plan — and new course offerings — aim tobring a renewed commitment to continuous educationat the Labs. Program categories include engineering,bioscience, material science, energy surety, and com-puter science/software engineering. Data show that pro-gram participants are applying knowledge and skillsgained from the training directly to their work and thatthe Technical Education Program is on target in meet-ing core and critical needs of the Labs. (3500)

Employee and Labor Relations, in partnership withCorporate Education, Training, and Development, hasimplemented a Tier Career Path Development Pro-gram. This program created a curriculum and learningopportunities that strive to enhance the existing skillsof Tier employees and help develop new skills. It willalso help ease the consistent labor shortage and preparemore qualified internal bidders for available Tier posi-tions. Other represented employees have found theprogram resources beneficial. The Tier Career PathDevelopment Program is open to all representedemployees and received a Turquoise PQA in 2004.

The Integrated Safety Management System Soft-ware program is the cornerstone of ES&H manage-ment at Sandia. Rewritten during 2004 to becomeweb-based, ISMS Software incorporates requirementsfrom DOE, federal law, and subject matter expertiseinto simple-to-use programs that establish safetyenvelopes and environmental requirements for alloperations. Reporting capabilities allow users toretrieve information in PDF reports or Excel spread-sheets. Creation, editing, review, and approval activi-

ties are simplified, saving up to two-thirds of the timeneeded to train users and produce safety and environ-mental documentation. (9500, 6300).

Sandia’s Secure IP Videoconference team wasawarded the National Nuclear Security Administration(NNSA) Defense Programs Award of Excellence fordeploying a Nuclear Weapons Complex (NWC) securevideoconference capability. The team led six NNSAorganizations in deployment and certification of across-organization secure communications resource.The secure IP-based videoconference capability is nowroutinely used throughout the nuclear weaponscomplex with the capacity to support 24 locations con-nected simultaneously. The capability is designed tosupport full digital collaboration capability, includingdata sharing, visualization, and model manipulation.

A cross-functional team implemented best prac-tices in developing an integrated and comprehensivemethod of orienting Sandia/California new hires. A sys-tem approach ensured the program was embraced by allstakeholders and that the design incorporated a holisticfoundation. Quality metrics were imbedded to drivefor continuous process improvement. The programreceived an ERA award and was also cited by CorporateInternal Auditing as an observed area of excellence,being described as “professionally developed, thorough,comprehensive, and effectively delivered.” (8500)

The Ninth Annual Student Internship Symposium,held last August at the Albuquerque Convention Cen-ter, brought together approximately 800 attendees,including 475 Sandia student interns, with 225 internsparticipating with oral and poster presentations. Morethan 30 exhibitors represented 20 different organiza-tions ranging from fellowships, colleges and universi-ties, and Lockheed Martin recruiters. (3500)

Sandia’s Disease Risk Management Clinic hasdemonstrated that many of the complications of diabetescan be prevented through education, treatment with dietmodification, exercise, and new pharmacologicalapproaches. The clinic is currently helping some 800employees and has expanded to include the manage-ment of high blood pressure and cholesterol. For self-insured employers, the focus on providing optimal careto those individuals with chronic disease has been shownto be an effective cost-containment strategy. (3300)

Sandia signed an MOU with the Inter-Tribal Eco-nomic Alliance (ITEA) and Intertribal InformationTechnology Company (IITC) to develop and deploytechnologies related to microsystems, aging aircraft, and

manufacturing. ITEA and IITC are owned by a strategicconsortium of sovereign tribes, Alaska native corpora-tions, and native Hawaiian organizations for businessdevelopment in Native American communities. (12100)

In FY04 Contract Audit, Procurement, and OracleProject departments implemented Phase I of the Inte-grated Contract Audit System. The system integratesaudit data with supplier, purchase, and invoice datainto one information system. It allows timely resolu-tion of audit findings, and provides one-stop shoppingof contract audit information for Contract Audit, Pro-curement, Accounts Payable, Travel and Treasury, andline personnel. The system allows tracking of auditablecontracts from identification to final closeout, and tofinal payment or collection activities. (12800)

The Management Advisory Services Team becamemore firmly established during FY04. A small team pro-vides special studies of pressing management issues forsenior management. For the first time since its incep-tion in FY02, the team has a backlog of study requests.Additionally, the team initiated an information serviceto alert management of developing issues from out-side Sandia that might prove applicable here. This“environmental scan” will provide an additional mech-anism of ‘early warning’ to Sandia executives. (12800)

Senior managers from across the company performedan in-depth review of the Columbia space shuttle accidentto understand lessons learned for Sandia’s high-risk opera-tions. The resulting briefing directed managers to considerissues associated with understanding and managingrisks, ensuring adequate and deep technical understand-ing, decision-making with particular emphasis on commu-nications, and key elements of safety culture. All managersin the company were briefed and urged to reflect thelessons learned in their daily operations. (12300, 2100,4100, 8200, 9100, 9700, 12100, 15400, 16000)

Video streaming proved to be a key communicationtool on the SRN. The fiscal year began with an aver-age of 8,000 video streams viewed per month. By theend of the year we averaged just under 14,000streams per month. In November 2003 a significantamount of content was required as part of the Securitystanddown. Many presentations were available to viewvia streaming. We had 175,000 video streamsaccessed during the month of November, clearlydemonstrating the viability of streaming. (12600)

ES&H Performance Assurance developed an Injuryand Illness Predictive Model which will help Sandiadecrease the number of employee injuries. This tooluses a customized approach to identify characteristicsthat can forecast the risk of injuries within an organiza-tion, so interventions can be applied precisely whereneeded. To date, Lockheed Martin and Liberty Mutualhave expressed interest in this methodology. (6300)

COMMUNITY INVOLVEMENT continued to have avery positive impact. We distributed more than $2million in corporate contributions to our communi-ties. Our employees and retirees donated morethan $20,000 to Shoes for Kids, which enabled usto fit school children from 20 elementary schools.More than 170 Sandia volunteers participated in 10projects for Make a Difference Day. More than 275volunteers last summer completed our fifth Habitatfor Humanity House (photo of Habitat family below).

Overall, our volunteers donated almost 90,000 hoursto community projects. In addition to the corporatecontributions, Sandia employees pledged morethan $2.5 million for the 2004 Employee Contribu-tion Plan/United Way/Livermore Employees Assis-tance Program Campaign. Funds donated by Sandi-ans supported community efforts such as CuidandoLos Niños in Albuquerque, which provides care forhomeless children. In the photo at left, Cuidandovolunteer “granny” Beulah Haynes comforts a child.

IES: Integrated Enabling Services(Continued from preceding page)

Page 15Labs Accomplishments • March 2005

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Sandia National LaboratoriesPage 16 • Sandia Lab News

The Sandia Chile Meter is an intelligent image-based system for automatically measuring the

amounts of chile and trash in chile processing oper-ations. It is being used to optimize the configurationand effectiveness of a mechanical chile cleaner in aneffort to improve automation in the state’s $200million/year industry. Intelligent Systems andRobotics Center 15200 has been working on theautomation problem with the New Mexico ChileTask Force, an industry and university consortium,through Sandia’s New Mexico Small BusinessAssistance program. (15200, 1300)

The Navy Wolf-Pack (MTA+Tech Partnership Busi-ness Development Team) successfully initiated a newNavy relationship that cascaded through four NavyProgram Offices (including Carriers, Deepwater Ships,Coast Guard, and Naval Air) and produced four mem-oranda of understanding. The relationship affords theopportunity to work with 11 defense contractorindustry partners to provide pathways for Sandia sys-tems solutions for the war fighter. Initial funding hasreached DOE, and Phase One tasks have been accom-plished. (1300, 15000)

The Sandia Science & Technology Park continuesto foster economic development in New Mexico. Itattracted four new tenants in FY04: Ktech, SunwestCAD, Heel, and Sandia’s Controller and Pension PlanManagement Center. The Park now boasts 19 compa-nies employing almost 1,100 people. An economicimpact analysis in 2004 found that the average salaryfor each job in the Park was $55,000 and also deter-mined that the Park created an additional 3,200 indi-rect jobs. Public and private investment in the Parkexceeds $161 million. (14000)

Sandia’s Military & Technologies Application busi-ness unit has established a new strategic partnership

with Rockwell Collins. On Oct. 1, 2004, DOE approveda five-year umbrella CRADA with Rockwell Collins.On Oct. 5, 2004, Rockwell accepted Sandia’s first pro-ject and task. The project will conduct and documenta capability study to identify how Sandia’s expertise inthe area of high-density interconnect substrates, ther-mal management, and RF power transistors can beapplied to support Rockwell Collins’ development of aminiaturized data link. This effort will support the AirForce Research Laboratory Weapon Data Link Architec-ture Program.

Sandia and Waters Corporation successfully con-cluded a three-year CRADA to develop an electroki-netically pumped high-pressure liquid chromatog-raphy system. Biomolecule separations weredemonstrated with a prototype microfluidic gradientsystem. The work resulted in record-setting microflu-idic performances in high-pressure electrokineticpumps exceeding 55,000 psi, nanoliter flow sensors,ultra high pressure microfluidic valves, and high-pres-sure plastic microchip materials fabrication processes.Nine patent applications were filed. These technolo-gies are being commercialized by Waters and incorpo-rated in Sandia Chem/Bio Detection programs, DHSBioBriefcase, and DoD µChemBioLab. (8100, 8300,8700, and 8500)

Eleven bellwether emergency responders fromacross the nation met for two days with Sandians andrepresentatives of Smiths Detection last summer. Devel-opers of the uChemLab Chem/bio detector met face-to-face in no-holds-barred discussions with peoplewhose lives might depend on the performance of oursystem. In broader discussions, we shared the possibili-ties of a range of Sandia technologies and confrontedrealities of real-world conditions and situations. Welearned from each other and began enduring personalrelationships. (8300, 8100, others)

THE SANDIA CHILE METER uses imaging technology to scanred chiles (photo below) to produce digital, analyzable images(top of page) to help optimize the efficiency of a mechanicalchile cleaner (photo immediately above). Sandia’s involvementin the project was made possible through tax credits grantedby the New Mexico Small Business Assistance Program.