LA 2001 complete - public.ca.sandia.gov€¦ · engineering, modeling and simulation, and process...

LIGHTING THE WAY — Keven Krenz (8420) briefly doffs hisface mask for a photo at the chamber of the extreme ultra-violet lithography device where workers align light used topattern circuits in this potential next-generation approach

to microchip manufacturing. Sandia is making the EUVLtool as part of the largest-ever funds-in DOE CRADA($250M over 5 yrs). See the EUVL entry below.

(Photo by Randy Montoya)

Toward the beginning of each calendaryear the Lab News sums up Sandia NationalLaboratories’ principal achievements duringthe previous fiscal year. This issue of LabsAccomplishments continues that tradition.

All Sandia divisions were invited to sub-mit achievements; submissions selected bythe VPs’ offices are presented on the followingpages. The work was accomplished mostlyduring the fiscal year that ended Sept. 30,2000. Key Sandia organizations contributingto each accomplishment are in parentheses atthe end of each entry. Also — new this year— a key contact name and e-mail address foreach submission are included.

You’ll note that the work is presentedhere by category. We find this organizationalapproach to be helpful, but it is important torecognize that such categorization, particularlyin a multiprogram, multidisciplinary laboratorysuch as Sandia, is to some extent arbitrary.Much of the work listed under the category“Nuclear weapons,” for example, could veryappropriately have been listed under “Micro-electronics” or “Computing.”

PartnershipsExtreme Ultraviolet Lithography (EUVL)

extends current lithography capability to the sub-100 nanometer feature size, allowing fabricationof microprocessors with 100 times the speed and1,000 times the memory of today’s integrated cir-cuits. Sandia activities in EUVL include precisionengineering, modeling and simulation, andprocess development activities. Once complete,the EUVL tool will be capable of printing featuresas small as 70 nm. This program is the largest-everfunds-in DOE CRADA ($250M over 5 yrs). (8400,8700, 2300, 2200) Bill Replogle, [email protected]

The Southwest as a Region of InnovationConference 2000 brought together representa-tives from Arizona, Colorado, New Mexico, andUtah to work toward creation of a southwesternMicrosystems Industry Cluster. The Albuquerqueconference attracted 338 attendees who discussedhow to form this cluster and focused on using themicrosystems expertise, facilities, and resourcespresent in the Southwest. A regional LeadershipTeam was formed and is working toward thiscluster creation. The new Microsystems andEngineering Sciences Applications facility is

envisioned as the cluster cornerstone facility.(14000, 1000, 1300, 1700, 1900, 12100, 12600)Jackie Kerby Moore, [email protected]

Sandia and ten industry partners have signedthe Cold Spray Consortium cooperative researchand development agreement, under which theLabs will develop and commercialize Cold Spraytechnology over three years. In this process,metal or composite powders, accelerated to highvelocities in a compressed gas jet, bond to a targetsurface by a process similar to explosive welding,but on a micro-scale. Depositing metals/compos-ites in the solid state opens exciting new designand manufacturing possibilities. (1800, 9100,1300) Mark Smith, [email protected]

Sandia researchers, in partnership with theUNM Cancer Center, were instrumental inobtaining a $1 million grant for UNM Health Sci-ences from the Keck Foundation to support devel-opment of new tools for research in functionalgenomics. By combining optical imaging devicesdeveloped as part of our satellite program,chemometrics data analysis routines developedfor materials characterization, and datamining/visualization software (VxInsight ™),

Special Section January 26, 2001

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To all Sandians:In Donald Stokes’ book Pasteur’s

Quadrant, it was suggested that the bestmodel for advancing science and technology

may well be toseek new “under-standings” whilealso seeking new“uses” for sci-ence and tech-nology. It is amodel we atSandia greatlyrespect.

This year,the challenge ofmarrying usewith under-standing appearsto have beenwell met. Thisreport chronicles

many accomplishments, large and small, bytechnical teams, support staff, and individualresearchers. I believe you will agree with methat Sandians have made many importantadvancements.

Great significance, new possibilitiesSome of the achievements are already of

great significance, like the innovations thathave kept America’s nuclear weapons safeand reliable. Others opened up new possibil-ities to create new strengths for the future,including advances in short-pulse lasers; inultra-high magnetic pressures; in nanotech-nology; in miniaturized sensors and circuitry;in missile defense targets and advanced satel-lites; in new energy conversion technology;and in supercomputing, information sys-tems, and cybersecurity.

The greatest privilegeThe opportunity the nation affords us to

participate in the creation of new knowledge,as we also help to solve important nationalproblems, makes working in the Laboratoriesperhaps one of the greatest privileges any cit-izen can have.

C. Paul Robinson

Labs Director and President

A note to readers

SANDIA LAB NEWS • Labs Accomplishments 2001 •

Partnershipsthey proposed, and were funded todevelop, a next-generation gene chipmicro-array scanner. (1800, 9200,5700) David Haaland,[email protected]

The New Mexico Legislature passedlegislation that allows Sandia to earn atax credit of up to $1.8 million inreturn for assisting small businesses inthe state. Through its New MexicoSmall Business Assistance Program, San-dia is using Labs expertise and capabili-ties to help small businesses resolvetechnological problems or businessissues. The program is geared to helpretain current small businesses, gener-ate additional employment opportuni-ties, and expand the base of suppliers for Sandiaand other large entities in New Mexico. (1300,12000, 14000) Olen D. Thompson, [email protected]

Recent licenses with startups MEMX Inc. andNovint Inc., grant Sandia an equity position ineach company in exchange for rights to developbusiness around Sandia intellectual property.These first-of-a-kind (for Sandia) equity licensesoffer an opportunity to share in the companies’technical developments and financial successeswhile enabling Sandia to better meet its nationalsecurity missions by developing a regional sup-plier base through the licensing of importanttechnologies. Novint is launching products basedon haptics, a technology that adds the sense of

touch to 3-D computer interfaces, while MEMX, aspin-off company from Sandia’s microelectro-mechanical systems (MEMS) development activ-ity, will commercialize a MEMS-based opticalswitch for the telecommunications industry.(1300, 1700, 9200) Olen Thompson,[email protected]

Sandia and industry partners have launchedthe Radio Frequency CRADA to explore the pos-sibility of commercial manufacture of complexelectronic assemblies for weapon applications. InFY00 this CRADA delivered prototype assembliesproduced on state-of-the-art automated manufac-turing lines, using commercial off-the-shelf com-ponents, at a fraction of the cost traditionallyincurred for similar products. Continued success

of this CRADA may significantlyreduce the cost of RF assemblies forweapon needs in the future. (2300,1700, 1800, 14100, FM&T) Ron Diegle,[email protected]

Sandia and other organizations inDOE’s nuclear weapons complex(NWC) renegotiated a volume pur-chasing agreement with ParametricTechnology Corporation for use of itsPro/E software, the standard 3D solidmodeling tool used by the weaponsprograms. The deal saves Sandia $1/2million. The three-year agreementcovers 226 Sandia users of Pro/E, andincludes the flexibility to adjust thatnumber to accommodate changingprogram needs. This effort representsthe establishment of a significant part-nership between members of theNWC and a key software provider forthe complex. (2900, 10200) CharlesFleetwood, [email protected]

Sandia licensed its technology in a unique,emerging microelectromechanical systems tech-nology known as LIGA to photonic subsystemprovider AXSUN Technologies. LIGA, anacronym from the German words for lithography,electroplating, and molding, is a technique thatallows precise microstructures to be fabricatedfrom metals, plastics, and ceramics. After a suc-cessful prototyping effort at Sandia, AXSUN com-mitted to establishing a Livermore-based LIGAproduction facility. The facility will manufacturealignment structures for use in AXSUN’s opticalproducts. The licensed Sandia know-how enablesAXSUN to more quickly establish productioncapabilities. (8700, 11600) Jill Hruby,[email protected]

Sandia has successfully simulated a sectionof the RHP (radiation-hardened Pentium)microprocessor using the Sandia-developed Chile-SPICETM circuit simulator. Production runs usingChileSPICE have reduced simulation time from3-10 times when compared to commercial simu-lators. The increased performance and enhancedconvergence technologies will lead to improvedcircuit designs on a much larger scale than can beachieved today. Initial performance evaluationsof XyceTM, the next generation massively parallelcircuit code, show a dramatic improvement in cir-cuit simulation performance. (1700, 9200, 8400,2300, 9300) Steven Wix, [email protected]

We have made significant advances in theparallel performance and physical fidelity ofour suite of electromagnetics and plasma physicscomputational tools, collectively named EMPHA-SIS. EMPHASIS is used to qualify systems tointense electromagnetic and X-ray environments,

design high-frequency electronics, and modelpulsed power components. We are using it toassess shielding effectiveness of a Lockheed Mar-tin system. One EMPHASIS tool has demonstratedperformance of 1 trillion operations per secondon Sandia’s teraflops computer. Another hasnovel algorithms to dynamically balance thecomputational load. (1600, 9200) Mark Kiefer,[email protected]

A microstructure-property material modelthat can predict the accurate stress and failureresponse for component designs and/or manufac-turing processes received an R&D100 award. Threeexamples exemplify the model. The size/weight ofautomotive components was lowered resulting inreduced emissions and conservation of fuel. Themultiphase aspect of the material model was usedin a commercialized heat treatment simulationtool for process design involving carburizing andquenching phase transforming alloy steels. Third,the model was used to optimize die design in aweapons component forging process. (8700) MarkHorstemeyer, [email protected]

Predictive modeling of the dynamics of struc-tures with bolted interfaces is of broad engineeringinterest. The damping generated in bolted joints isparticularly difficult to model. A combined exper-imental and analytical program initiated at Sandiafocused on the damping mechanisms in boltedinterfaces and led to the discovery of an underly-ing power law relationship between the appliedforce and the energy dissipation per cycle.Promising reduced-order analytical models devel-oped will be important to successful modeling ofweapon system structural performance. (9100)Dan Gregory, [email protected]

The GOMA software team has used its broadcustomer base in defense programs and industryto guide successful research, code development,and analysis projects. In an effort to bring a sci-ence-based understanding to manufacturingprocesses, the GOMA team has worked with man-ufacturing personnel and material scientists inthe areas of welding, brazing, cermet processing,and encapsulation. Driving projects from model

development to code implementation andfinally performing high-fidelity engineeringanalysis has required a team effort with a respectfor the talent each member brings to the team.(9100, 9200, 1800, 8700) Justine Johannes, [email protected]

The SALINAS massively parallel 3D struc-tural dynamics code was used to complete criti-cal simulations of W76 system response tohostile radiation environments, running for 24hours on 2000 ASCI Red processors. Sensitivityand optimization analyses were performed onthe arming, fuzing, and firing (AF&F) modelusing Sandia’s DAKOTA software package. Ahigh-fidelity model for timing and scaling stud-ies was generated with CUBIT advanced mesh-ing software. The Sandia team greatly exceededthe milepost success criteria, demonstratingcapability beyond anything commercially avail-able. (9100, 9200, 9300) James Peery, [email protected]

Engineering Sciences

MEMX SPINS OFF — Four Sandia researchers have agreed to join a private spin-off company,MEMX, Inc., to commercialize Labs-developed microsystems technology. They are, from left,Paul McWhorter, Sam Miller, Jeff Sniegowski, and Steve Rogers. (Photo by Randy Montoya)

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RESULTS of a simulation for the USCAR CRADA showthat Sandia’s microstructure material property modelpredicts the exact location of the initial failure site. Themodel prediction was performed ahead of the test toensure its predictive capability. Note that the predictedinitial failure site was identical to the experiment.

EMPHASIS calculated magnetic fields in a cavity contain-ing cable-connected circuit-board modules in responseto an external electromagnetic environment.


Sandia made significant contribu-tions to the Nation’s missile defenseeffort during the previous year in theareas of targets for system testing, lethal-ity, threat and countermeasures, andnavigation, guidance, and control. Weprovided target objects for threeNational Missile Defense IntegratedFlight Tests and two National MissileDefense Risk Reduction Flights. Sandiaalso provided high-fidelity, scaled targetsfor lethality impact testing, and sup-ported the analyses of the data fromthese tests with over 100 high-resolutionhydrocode calculations. In addition,Sandia is providing the navigation, guid-ance and control system for the first twoNational Missile Defense interceptor pro-totype booster systems. Jerry Langheim,[email protected]

The Advanced Firing & DetonationSystems and Microsystems Advanced &Exploratory (A&E) projects demonstrateda wide range of new technologies forfuture firing system applications innuclear weapon refurbishment and DoDfuzing options. These included SurfaceMicromachine (SMM) and LIGAstronglinks, Direct Optical Initiation(DOI) firing sets and micro-DOI concepts,optical charging and triggering of Capaci-tive Discharge Units (CDUs), and severaltechnologies necessary for microfiringsets. Several demonstration units werefabricated in partnership with the KansasCity plant. (2000, 2100, 2500, 1700,1100, 1800, 8400) Larry Hostetler,[email protected]

The most detailed structural dynamicmodel validation experiments ever per-formed on a nuclear weapon system werecompleted this year on the W76/Mk4Reentry Body (RB). These experimentssuccessfully identified modes of vibra-tion as high as 1,000 Hz for the RB andeach major subassembly. The test seriesdiscovered significant unit to unit vari-ability for frequencies above 1,000 Hz. Data gath-ered from multilevel shock and vibration inputswill be critical to the validation of high-fidelitymodels that mimic the nonlinear behavior of realweapon structures. (9100, 2100) Randy Mayes,[email protected]

New Weapon Evaluation Test Laboratory(WETL) autho-rized: After operat-ing in a more than30-year-old pre-fabbuilding for years,the constructionconcept for a newstate-of-the-art facil-ity for Sandia sur-veillance programspassed its final hur-dle, the DOE Exter-nal Review. Designfor this $24 million facility will be done this year,with construction the following two years. Blend-ing the best of the reshaped core surveillance andenhanced surveillance program, this modernfacility that will begin to move the DOE toward apredictive capability. (2900, 7800, 9500) W. L.Norris, [email protected]

Working with our counterparts at the KansasCity plant we designed and built two versionsof prototype firing sets for the W76 Arming, Fuz-ing, and Firing life extension program. Throughthe use of simulation and rapid prototyping toolsand techniques, we were able to go from paperdesigns to hardware, demonstrating form, fit, andfunction in less than a year. In addition, thesetools allowed us to evaluate and solve a variety ofdesign and manufacturing issues before the proto-types were fabricated. (2600) Jim Hole, [email protected]

Sandia’s Military Liaison Department, inpartnership with the DoD and the military,implemented an upgraded Unsatisfactory Report-ing system for nuclear weapons, ancillary equip-ment, and publications. The system, known asthe “Workflow Enabled UR System,” has yieldeddramatic improvement in tracking steps in theprocess and sped up the answer to the operational

unit. DOE recognizedthis effort through theDOE/AL PerformanceExcellence Award for theWeapons Surety Divi-sion’s Weapons LogisticsQuality Program (SilverMedal). (2900, 9500)J. Mike Rhoads,[email protected]

On Sept. 22, 2000,the W76-0/Mk4 became

the first enduring stockpile weapon to completethe DOE Seamless Safety Process for Disassem-bly & Inspection operations at the Pantex plantin Amarillo. The project included development ofnew tooling, new procedures, a Weapon SafetySpecification, a Hazards Analysis, and hazardscontrols. DOE authorization for W76 operationsmakes it possible to conduct weapon surveillanceassessments at Pantex, which provide essentialinformation about weapon reliability and state-of-health. (2100, 1600, 8400, 12300)J. Paul Atencio, [email protected]

The Nuclear Weapons Council has authorizedinitiation of the W76 Life Extension Project.Authorization was the culmination of a multiyeareffort to assess the warhead state-of-health,develop refurbishment options, and generatemanagement processes and plans to meet aggres-sive requirements. The conceptual design incor-

porates new perfor-mance options andchallenges Sandia toimplement technicalinnovation and employ new modeling andsimulation tools. Key to winning authoriza-tion was our systematic scrutiny of require-ments and design options, our plan to reuseselected components, incorporate high-grade commercial electronic parts, stream-line production and qualification processes,and rigorously manage risk. (2100, 1700,2300, 2500, 2600, 8400, 9100, 9800, 12300,15300, and KCP) Patrick Sena,[email protected]

Using modern predictive analyses cou-pled with limited field testing, the B61-11ALT 349 weapon design was certified forstockpile use by Sandia and Los Alamosnational labs. The final Design Review AndAcceptance Group (DRAAG) meeting for theB61-11 ALT 349 was held in September atSandia. The DRAAG wields the authority toaccept/reject a weapon for use in the stock-pile. The design was recommended foracceptance as a standard stockpile item bythe DRAAG to the Nuclear Weapons CouncilStanding and Safety Committee in Decem-ber 2000. (NW) Kevin Eklund,[email protected]

The In situ-Impregnated Gel Capacitoris being developed as the energy storagedevice in firing sets for several Stockpile LifeExtension Programs (SLEPs). The gel/Mylardielectric system results in a volume reduc-tion greater than two when compared to theair/Mylar dielectric used in the majority of fir-ing sets for the enduring stockpile. Further, acost savings of almost an order of magnitudeis realized when compared to older dielectricsystems used in other stockpile weapons. Theprocess has been successfully scaled up from10 to 80 capacitors per run. (1700) L. RogerEdwards, [email protected]

The In-Ground Storage Vault (IGSV)was designed and constructed to providehigh-security, temporary (two-year) storagefor the Sandia Pulsed Reactor (SPR) fuelmaterials. This state-of-the-art facility yields

annual security cost savings of approximately $6million and is the first step in a comprehensiveplan to insure that the SPR is available at a rea-sonable cost to meet essential nuclear weaponstesting requirements. That plan will culminate inconstruction of a new high-security SandiaUnderground Reactor Facility (SURF) to housefuture SPR operations. (6400, 5800, 7100, 7800)Kenneth Reil, [email protected]

The DOE National Nuclear Security Adminis-tration Office of Transportation Safeguards (OTS)must meet the highest security standards becauseits mission is critical to the continued effectiveoperations of the nuclear weapons complex. San-dia was directly responsible for four of six manda-tory milestones required to obtain acceptable OTSsecurity ratingsfrom DOE HQ,and ensure unin-terrupted opera-tion of the trans-portation fleet.All milestoneswere met, andthe OTS securityrating wasupgraded. (NW)M. Brad Parks,mbparks@ sandia.gov

Reliabilityand data credi-bility probabil-ity analyses havebeen completed for the B61-7/11 and RedesignedW76 Type 2F telemetry systems. Both studiesused a new methodology for estimating the relia-bility of commercial parts, as well as a software

Nuclear weapons

MINUTEMAN 2 BOOSTER launched from Vandenberg Air Force Base, Calif., aspart of the National Missile Defense initiative, in which Sandia provided targetobjects and other vital support.

ARTIST’S CONCEPT of new Weapon Evaluation Test Laboratory.

IN THE CAB of an armoredSafeguards tractor.



Nuclear weapons

tool that allowed for examination ofkey contributors to unreliability. Areport has been published document-ing the results of these studies. In addi-tion, a complete description of thegeneral methodology for analyzinginstrumentation systems (both relia-bility and data credibility) has beenincluded in the study report. (8400,12300) Rene Bierbaum,[email protected]

A Sandia team in collaborationwith Lawrence Livermore NationalLaboratory and Lockheed Martindesigned and flight tested a warheadconcept under the Submarine-launched Warhead Protection Pro-gram (SWPP). Warheads currentlydeployed by the US Navy weredesigned and certified prior to cessa-tion of underground nuclear testingand the closure of major DOE weaponcomponent facilities. The SWPP PitReuse Project investigated potentialfuture replacement options. While nostockpile hardware is intended, the flight testexercised DOE/DoD interfaces and exposed newstaff to this important national security mission.(2200, 2600, 8400) Bill Wilson, [email protected]

Sandia contributed to the successful comple-tion of the Phase 6.2/6.2A study for the W80life extension program (LEP). The NuclearWeapons Council accepted the recommendationsprovided by the study team and approved entryinto Phase 6.3, with a first production unit date ofFebruary 2006. The W80 Phase 6.3 represents asignificant effort for Sandia, requiring newdesigns for the entire warhead electrical system,neutron generators, gas transfer system, and sev-eral new mechanical structural components.(2100, 2200, 2300, 2600, 8400, 10100, 12300)Doug Gehmlich, [email protected]

The W76 Joint Test Assembly telemetry sys-tem redesign was employed in a re-entry body,which was launched from a submarine in Febru-ary 2000 as a “Follow-on CINC Evaluation Test.”The flight resulted in a successfully scoredweapon system test. Advancements in spaceradiation tolerance were proven, as was the effi-cacy of the Modular Telemetry Design Methodol-ogy as a design tool. An important first for thisdesign was the digitization and transmission ofneutron and firing system waveforms. Thisinstrumentation system is significantly morecomplex, having ten times the data rate of theoriginal, yet the production costs are significantlyless. (8400, 2100) Art Hull, [email protected]

Tech transfer comes full circle: Organichydrogen getters, invented by Sandia to scavenge

unwanted hydrogen in various systems, havebeen reinvented, patented, and commercializedthrough a 100-percent funds-in cooperativeresearch and development agreement with Vac-uum Energy Inc. Sandia’s hydrogen reductiontechnologies are now found in numerous con-

sumer and industrial products. Millions of unitshave been purchased for products such as flash-lights, refrigerators, and heat exchangers. Theadvanced getters created for consumer marketsare now being certified for the shipment ofradioactive materials within the NuclearWeapons Complex. (8700, 6100) Tim Shepodd,[email protected]

The Nuclear Weapons Strategic BusinessUnit (NW SBU)developed anddeployed its QualityManagement Systemand Policy for orga-nizations that per-form work for theSBU. The manage-ment system pro-vides taxonomy forthe SBU and itsrequirements,processes, and prod-ucts and is based onISO 9000, thenationally recog-nized set of Qualityguidelines. The pol-icy provides high-level direction forthe SBU and internal

requirements to support its advance-ment. Policies and Processes can befound from the Sandia home pageand the NW SBU button. (9000,1000, 2000, 8000, 12300, 14000)Mark Dickinson, [email protected]

We have completed an assess-ment of Sandia’s current and long-term equipment recapitalizationneeds for capital-intensive facilitiesthat support the Defense Programs(DP) mission. A methodology wasdeveloped to assess needs based ondifferent levels of potential futurecapability for each facility and to esti-mate the associated labor and expensecosts for each level. Capital equip-ment investment at Sandia hasdeclined dramatically since the 1980s.The study is intended to provide astarting basis for developing capitalequipment strategies and priorities forfuture DP needs. (9800) KeithAlmquist, [email protected]

The multidisciplinary MAVENFire Team demonstrated that labora-tory-quality diagnostics, particle imagevelocimetry, and planar laser-inducedfluorescence could be brought into afield-test-scale facility and used toobtain velocity, temperature, andspecies concentration validation data.We completed a test series involving

42 experiments for a one-meter-diameter flow forhelium plumes and methane and hydrogen fires.Limited data analysis has been completed andcompared with Large Eddy Simulation computa-tions. These data will be applied to validate trans-port models in the FUEGO fire code. (9100, 6400)Gene Hertel, [email protected]

The Security Matrix Project, jointly charteredby DoD’s Office of the Assistant to the Secretaryof Defense (Nuclear-Chemical-Biological)/Nuclear Matters and DOE’s Defense Programs-20,provided an integrated assessment of weaponsecurity and use control. Team members vis-ited all US sites where weapons are held and con-ducted in-depth analyses of locations, weaponconfigurations, site infrastructure, and physicaland operational security. The study played a sig-nificant role in the W80 Lifetime Extension Pro-gram and led to changes in Air Force securityposture, Navy/Marine Corps security capabilities,and overall DoD security requirements. (12300)Timothy Petersen, [email protected]

The W76 SLEP down-select for Phase 6.3 forthe Navy Mk4A weapon systems occurred inJuly. A 12300 independent Weapon AssessmentTeam reviewed the warhead candidates for qual-ity, reliability, nuclear safety, stockpile surveil-lance, and security/use control attributes andeffectiveness. The Weapon Assessment Teamconfirmed the Preferred Option candidate,recommended by Div. 2000, as a viable designthat enhanced reliability over the extended life-time and afforded nuclear safety and significantuse control enhancements to the present base-line W76 design. The selection of the BaselineOption was made with idea of a block upgradeapproach, where the surety advantages of thePreferred option could be incorporated at a laterdate. (12300) Frederick Trussell, [email protected]

In FY99, a new approach to evaluatingweapon safety in thermal accidents was devel-oped. This approach (the FINDV code) uses theALASKA distributed computing platform to evalu-ate probabilistic weapon safety for a wide range ofscenarios. Thermal responses are obtained usingthe COYOTE code. In FY00, this process was usedto evaluate candidate design options for the W80Lifetime Extension Program (LEP). A wide varietyof engulfing, planar, and directed fire scenarioswere evaluated and compared against similarresults for the design currently in the stockpile.These comparisons showed that the downselectedOption 3a conceptual design has significantlyimproved safety performance in the range of fire

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MESA MOVES FORWARD — The conceptual design for Sandia’s Microsystems and Engi-neering Sciences Applications (MESA) complex has been completed. This major piece ofwork was a substantial effort for many organizations across Sandia. The final ConceptualDesign Report (CDR) was printed and distributed in May 2000. The effort led to theauthorization of funds to start the next phase (Title I/II Design) of the project. Comple-tion of the CDR is enabling Sandia and DOE to make investments which will create tech-nological capabilities to meet near-term and future mission needs for nuclear weapons.(1000, 2000, 6000, 7000, 9000, 10000) Don Cook, [email protected]

ANALOG ASIC — As the stockpile ages and electronic components show the first signs ofdegradation, Manufacturing Development Engineering (MDE) steps in to design and vali-date new War Reserve quality components that use technologies often many generationsahead of the old ones. These new technologies, once validated, are far more reliable andmany times lighter and smaller. MDE developed an analog ASIC used in an encryptiontranslator. The chip-sized ASIC replaces a much larger printed-wiring board (PWB) thatheld individual electronic components. Note that the Application Specific Integrated Cir-cuit at right is many times smaller than the printed wiring board circuit it replaces. (1700)Donald Evans, [email protected]

MAIN ELECTRONIC subassembly of the New W76Telemetry System .



Nuclear weapons

Sandia has significantly improved the accu-racy while also expanding the frequency range ofstructural dynamics models for the noise, vibra-tion, and harshness response of passenger vehicletires. These improved models have been experi-mentally validated and have directly led toimprovements in Goodyear’s relationship withvehicle manufacturers. Goodyear has stated thatthis effort has reached technical achievements“previously thought unattainable by industryexperts.” The experimental and analytical toolsand techniques developed during this partnershipare directly applicable to model validation forDOE defense programs. (9100, 9200, 2100) CurtNelson, [email protected]

By integrating Sandia-developed sensing,cutting, and contour generating technologies, across-organizational team led by the Labs’Robotics Center successfully demonstrated anautomated meat cutting system for industrysponsor IBP, Inc. Last September, the prototypedevice was shipped to IBP for further testing anddevelopment. The shipment marks Sandia’s suc-cessful completion of all technical tasks spelledout in the Sandia/IBP cooperative research anddevelopment agreement a year-and-a-half aheadof schedule and under budget. Sandia and IBPhave filed a number of technical disclosures andpatent applications as a result of this work.(15200) Jerry Langheim,[email protected]

The Sandia Science & Technology Park pro-gram office spear-headed the cre-ation of alandmark Memo-randum of Under-standing (MOU)that binds publicand private partiesto develop the 219-acre park just out-side the Kirtland AFB Eubank gate. The park aimsto attract technology-based companies. Signato-

Partnerships

scenarios examined (12300) Michael Bohn,[email protected]

A recent survey of the laboratory balancecalibration process revealed that some calibra-tions being performed were technically inade-

ries to the MOU include Albuquerque PublicSchools; New Mexico State Land Office; Shaw,Mitchell, & Mallory Limited Partnership; City of

Albuquerque;Sandia; and theScience & Tech-nology ParkDevelopmentCorporation. TheMOU was twoyears in the mak-ing and a neces-sary step for the

creation of a Master Development Plan. (14000)Jackie Kerby Moore, [email protected]

quate, leading to questionable calibrations. Thesurvey also showed that many balance userslacked proper training in the use of balances. Theprocess was improved to assure technically ade-quate calibrations and a user training programwas established assuring proper balance use. Cus-tomers are delighted with the process and nowhave confidence in the quality of the balancemeasurements they make using balances cali-brated by the Primary Calibration Laboratory.(2500) Jim Simons, [email protected]

The Purchased Material Team (PMT) waschartered by Neutron Generator (NG) ProductionManagement to develop and implement anoverall procurement process to ensure supplierquality for purchased neutron generator compo-nents. The team partnered with Honeywell’sFM&T division, a proven leader in meeting andmaintaining DOE requirements for supplier qual-ity. FY00 metrics showed that the team’s effortsled to significant improvements: PPA (percentparts accepted) from 80 percent to 96 percent andPATF (percent accepted trouble-free) from 62 per-cent to 86 percent. (14400, 10200) Lorraine Sena-Rondeau, [email protected]

The Manufacturing Development Engi-neering (MDE) program is a model for manufac-turing low-volume, high-reliability parts for theNWC. Since its inception in 1992, we haveachieved mission assignment requirements ofdelivering more than 40,000 components neededfor the enduring stockpile. More than 6,400 MDEparts were manufactured during FY00 by 12 pri-vate sector companies that have partnered withSandia’s design community in this critical nuclear

weapons program. Products manufacturedinclude: actuators, thermal batteries, igniters, gasgenerators, capacitors, magnetics, frequencydevices, and electronic components. (1700, 2500,14000, 10250) Eva Wilcox, [email protected]

The Manufacturing Development Engineer-ing (MDE) department designed and tested areplacement digital ASIC (application-specificintegrated circuit) microcontroller used in a spe-cific B61 configuration. During testing, a problemwas discovered with the memory working at coldtemperature. A failure analysis team worked fortwo months to pinpoint the problem. In order tobest use materials, the wafer lots in process werestopped at the silicide stage (before metal contactswere made) to accommodate a change in metalrouting. The fix was made and new masks wereordered to process the lots on hold. In November2000 the design fix was proved. (1700) TimMirabal, [email protected]

A high-voltage power transformer wasdeveloped for use in firing sets for several weaponsystems in the enduring stockpile. The originaltransformers had relatively low yields due tocracked encapsulation around and in the coreand/or separation between the contact assemblyand encapsulation. The MDE program developeddesign improvements such as use of a stress barrierbetween the core and the epoxy encapsulant andelimination of the contact assembly. Transformersproduced via this design are much more robustwith respect to mechanical environments. Morethan 250 war reserve (WR) transformers with thesedesign improvements have been successfully pro-duced. (1700) Wendel Archer, [email protected]

GETTING BALANCED — Jay Bennett (2544) calibrates alaboratory balance. These balances, used in labs through-out Sandia, are used to weigh chemicals, explosives, andother research materials.

General AtomicsLynx Synthetic Aper-ture Radar: The LynxSynthetic ApertureRadar (SAR) systemdeveloped by Sandiafor General Atomicshad several significantaccomplishmentswhich have resulted ina fielded demonstra-tion system for theArmy as well as provid-ing key support forDARPA-funded GroundMoving Target Indica-tor (GMTI) efforts. Thesystem was installed onthe Predatorunmanned aerial vehi-cle (UAV) including asatellite down-linkcapability for remoteoperations. It was alsoinstalled on Army U-21and C-12 aircraft. TheU-21 system was thenused in DARPA-fundeddata collectionsdemonstrating itsadvanced GMTI collec-tion capabilities. (2300)Jerry Langheim,grlangh @sandia.gov

A newly patented pressure indicatordesigned specifically for a medical application waslicensed to the cooperative research and develop-ment agreement partner Numotech, Inc. Thedevice monitors the pressure within the topicalhyperbaric oxygen therapy enclosure used to treathard-to-heal wounds including burns, diabeticulcers, and pressure sores. The device uses no elec-tricity, is inexpensive, disposable, has no enclo-sure penetration, requires no calibration, and isreadable from several meters. FDA has approveduse of the device. Keith Miller and Mark Vaughn(both 15252) are co-inventors. Jerry Langheim,[email protected]

SAR SCIENCE — Sandia researcher Bill Hensley checks the Lynx synthetic-aperture radar(SAR) installed on an unmanned aerial vehicle. During the past year, the Sandia-devel-oped General Atomics Lynx system attained several significant achievements, resulting ina fielded demonstration system for the US Army. (Photo by Randy Montoya)

(Continued from page 2)



Collapsing tunnels are disastrous inmining and transportation. In anatomic world, however, they can beextremely useful when they trap haz-ardous materials. Under the Environ-mental Management Science Program,Sandia scientists discovered a family oftunnel-collapsing materials namedSandia Octahedral Molecular Sieves(SOMS). When SOMS are submerged inwaste solutions, specific metals likeradioactive strontium stick inside itstiny tunnels. Heating the SOMS col-lapses the tunnels and traps the haz-ardous contents so they can be safelydisposed. Immobilizing the waste isvital to DOE cleanup efforts. (6200)Tina Nenoff , [email protected]

A new ion beam analysis facilityenables researchers to measure — non-destructively and in depth — the constituents(including tritium) of neutron tube targets andsources. Further improvements of the process

will enable War Reserve certification of ourbeam-line. This system serves the neutron tubescience program, which is closely coordinated

with the Labs’ neu-tron tube designand productionprocesses. (1100,2500, 14400) WilGauster, [email protected]

Sandia researchers,working with aninternational team ofscientists, developeda photochemicaltechnique for pro-ducing uniquenanostructures(hexagonally-packedtubes or 3-D tetrago-nal configurations).In the process, silicagels containingphoto-activated acidsare locally exposed toultraviolet light,

thereby engineering particular nano-structures. This photo-induced densifi-cation process has been shown sufficientto modulate the refractive index of theresultant material enough to make a dif-fraction grating or other optical device.This work was featured in a Science mag-azine article. (1800, 1100) M.J. Cieslak,[email protected]

The Low Energy ElectronMicroscope (LEEM) offers Sandiaresearchers an invaluable tool for learn-ing how certain combinations of atomsspontaneously self-order into stunningstructures consisting of nanometer-sizeddots, stripes, or polygons. Such nano-structured materials frequently exhibitunique mechanical, optical, or electronicproperties. Recent experiments providedthe elusive proof of a simple theory thatexplainshowinter-atomicforcescompeteto pro-

duce these struc-tures. Onceunderstood, self-assembly can beexploited to syn-thesize new classesof materials withtailored propertiesfor multi-func-tional, miniatur-ized actuating or sensing systems. (1100, 8700)Neal Shinn, ndshinn@ sandia.gov

Dynamics of Alloying at Surfaces: Whatare the atomic mechanisms when metals mix tomake alloys? Using a unique microscope, Sandi-ans Schmid, Bartelt, and Hwang (8700) discov-ered the surprising way bronze alloy forms whentin is evaporated onto copper. Microscopic tincrystals slowly shrink while “grazing” the coppersurface in an entertaining, almost life-likedance. To explain this peculiar motion, the teamproposes that a repulsion between tin atomswithin the crystals and tin atoms left in theirwake pushes the crystals forward, away from thebronze in their tracks. (8700) Andreas Schmid,[email protected]

Materials

Spontaneously formed pattern ofalternating lead and lead/copperalloy stripes imaged by LEEM.

MODEL of SOMS, showing its framework and tunnels.

OPTICALLY DEFINED multifunctional patterning of nanocomposites was the subjectof a Science article submitted by Sandia researchers working with an internationalteam of scientists.

Novel Methods to Study Radiation Symme-try in ICF Hohlraums: What does an architecthave in common with an inertial confinementfusion (ICF) target designer seeking 1 percentradiation uniformity at a fusion capsule? TheLightscape™ commercial lighting simulationpackage from the architecture world has beenadapted to accurately model radiation trans-port in complex 3-dimensional z-pinchhohlraums. Complementary research usesSandia-developed viewfactor codes and con-strained optimization algorithms to automati-cally find hohlraum geometries with optimalsymmetry. These are two examples of thenovel methods we recently developed to studyradiation symmetry in ICF hohlraums. (1600)Roger Vesey, [email protected]

The Annular Core Research Reactor was mod-ified to provide hostile environment testing forweapon components. The reactor was reconfig-ured for pulse operation with experiments locatedin the center of the reactor. Exceptional efforts bymany people enabled completion of high-levelprogrammatic goals for both ACORN and neutrongenerator programs. NNSA Defense Programsofficial Gen. Thomas Gioconda praised the reac-tor reconfiguration effort, which earned a DOENuclear Weapons Program Award of Excellence

and a Sandia President’s Gold Quality Award.John Guth, [email protected]

Pulsed power

A Revolutionary New Method for Launch-ing Flyer Plates with the Z Accelerator:Recently a new, revolutionary capability hasbeen developed at Sandia to magneticallylaunch macroscopic, hyper-velocity flyerplates. The large magnetic fields produced inthe insulating gaps of the Z accelerator havebeen used to “gently” accelerate relativelylarge aluminum, copper, or titanium flyerplates (9-12 mm in diameter by 200-300 mmthickness) to velocities in excess of 20 km/s.This technique is being used to perform equa-tion-of-state experiments with unprecedentedaccuracy in ultrahigh-pressure studies. (1600)Marcus Knudson, [email protected]

MAGNETICALLY accelerated flyer plate velocity as a func-tion of time. The large magnetic fields produced in theinsulating gaps of the Z accelerator have been used to“gently” accelerate relatively large aluminum, copper, ortitanium flyer plates (9-12 mm in diameter by 200-300mm thickness) to velocities in excess of 20 km/s.

LIGHTSCAPE™ simulated radiation flux contours inz-pinch ICF hohlraum.


Arms control and nonproliferation

On March 12, 2000, the USAF launched theMultispectral Thermal Imager (MTI) satelliteinto polar orbit aboard an Orbital Sciences Taurusrocket. MTI is a Sandia-led, multilaboratory R&Dproject sponsored by DOE’s Office of Nonprolifer-ation and National Security. Its objective is todevelop, demonstrate,and evaluate multi-spectral and thermalimaging and relatedtechnologies for abroad range ofnational securitycivilian applications.Brian Brock,[email protected]

Mayak Produc-tion Association is amajor Russian nuclearenterprise involvingnumerous plants thatprocess and storelarge quantities (esti-mated to be morethan 100 metric tons)of plutonium anduranium for bothweapon and civilianuses. Under the spon-sorship of the DOE Material Protection, Control,and Accounting (MPC&A) Program, the MayakProject has provided an initial design for largesteel-clad, steel-reinforced concrete blocks tocover canisters of plutonium dioxide in order toincrease the time required for a thief to gain accessto the canisters. An agreement was recentlysigned that establishes the foundation for initia-tion of security upgrades at another of Mayak’s

plants in which extremely large quantities ofweapons grade plutonium and uranium areprocessed and stored. (5300, 5800) Jim Chapek,[email protected]

We have designed, fabricated, and demon-strated prototypes of two portable chemicalanalysis systems tailored to the rapid detectionand analysis of toxic agents that might bereleased during a terrorist attack. Extensive test-ing of these prototypes with targeted agents (onefor chemical warfare agents and one for biotox-ins) has demonstrated that our devices can detectspecific agents with extremely high sensitivity invery short times. Furthermore, our tests haveshown that these systems are not affected bycommon chemicals that could potentially serveas interferrants. (1700, 8100, 8300)

Duane Lindner,dllindn@ sandia.gov

The AdvancedModular Tag (AMT) isa miniature, LPI/LPD(Low Probability ofIntercept/Low Proba-bility of Detection)communicator andtracking deviceintended for use byspecial operationsand other DoDforces. This work isfunded by the AirForce Space WarfareCenter; and, Centers5700 and 2300 haveteamed with Lock-heed Martin in thisdevelopment.Recently, the AMTsuccessfully passed a

critical series of laboratory and field tests requiredfor full certification and use with US assets. (2300,5700) Michael Murphy, mbmurph@ sandia.gov

Sandian’s best friend may be the newlydeveloped Hound™ — that is, if you need contra-band detection capabilities. The Hound™ is aportable sampling/preconcentration systemfitted to a commercial portable detector to

improve sensitive and sampling efficiency. Thisportable sampling/preconcentrator system is adirect outgrowth technology from the explosivesdetection portal (EDP) developed by Sandia forthe Federal Aviation Administration. The EDPand the HoundTM are capable of detecting vanish-ingly (parts per trillion) faint odors of explosivesand other chemicals. (5800) Kevin Linker,[email protected]

The Cooperative Monitoring Center is collab-orating with nuclear physics institutes in Kaza-khstan, Kyrgyzstan, Tajikistan, and Uzbekistan ina waterborne radionuclide monitoring experi-ment on the major rivers in Central Asia. Sincethe breakup of the Soviet Union, these countrieshave been pursuing independent courses, andcooperation on any issue has been extremely dif-ficult. These republics contributed greatly to theSoviet nuclear weapons program, from uraniummining and processing to nuclear weapons test-ing. (5300) Dave Barber, [email protected]

DOE’s AURA (Advanced UV Remote-SensingApplications) program completed a successfulengineering flight test deployment to DugwayProving Ground, Utah, last October. The AURApayload, an advanced ultraviolet laser induced flu-orescence lidar, was installed in the Altus UAV(Unmanned Aerospace Vehicle) and completed sixsuccessful flights. All science goals were met orexceeded. A second flight test deployment is set

MTI SATELLITE image showing the San Rafael Bridge north of Oakland and San Francisco, Calif. Vegetation shows up as bright red.

(Continued on page 10)

STEEL-CLAD reinforced concrete blocks are being placedon top of canisters of plutonium dioxide in storage tomake it harder for a thief to access the materials.

PAYLOAD PAYOFF — Sandia engineers Chuck Looney(left) and Dennis Gutierrez make last-minute checksof the solar arrays on the Multispectral ThermalImager (MTI) satellite at the Payload Processing Facil-ity at Vandenberg Air Force Base, Calif., prior toencapsulating the satellite in preparation for launchthat took place on March 12, 2000. Half of the satel-lite’s protective fairing (rocket nose cone) is visible inthe background with its internal (black) thermal-acoustic blankets. (Photo by Randy Montoya)

SAMPLING on the Chirchik River in Uzbekistan are, fromleft,Viktor Poznyak, Kazakhstan; Alexandra Inoyatov,Uzbekistan; Bajgabyl Tolongutov, Kyrgyzstan; RaisaRadyuk, Uzbekistan; Sandian Dave Barber; ValentinaAlekhina, Kyrgyzstan; and Djamshed Kamalov, Tajikistan.


for September 2001. The September test will repre-sent the first demonstration of an operational lidarfor the detection of WMD proliferation effluents.(Sandia centers that support the AURA programinclude 1100, 2300, 5700, 6100, 8100, 8300, 8400,8900, and 15400.) Al Lang, [email protected]

US/Russian Arms reduction treaties requireverification that nuclear materials from disman-tled weapons are not returned to weapons use.The Trilateral Initiative of the United States, Russ-ian Federation, and International Atomic EnergyAgency (IAEA) is developing a model verifica-tion agreement and exploring verification tech-nologies. Sandia provides a senior technical advi-sor and leads a group of technical experts for theUS delegation to develop inventory monitoringsystems and approaches for verification that areacceptable to all parties. (5300, 5800, 6500)Dennis Mangan, [email protected]

Mission Analysis and Simulation Dept. per-sonnel, using the Sandia Data Analysis and DisplaySystem, performed detailed mathematical and sta-tistical analyses of the more than 20,000 sensorevents collected during the Nuclear DetonationDetection System Characterization Test spon-sored by the Air Force Space and Missile SystemsCenter. Radio frequency illumination of the elec-tromagnetic pulse sensors onboard Global Posi-tioning System satellites was accomplished usingthe Stanford Research Institute pulser located atAlgonquinn Radio Observatory in Ontario,Canada. A comprehensive report was completed inAugust 2000. (6500) Bill Richard, [email protected]

Sandia delivered Release 4.0 of the NuclearExplosion Monitoring Knowledge Base to theUS National Data Center (US NDC). This Knowl-edge Base improves the ability of the US NDC todetect, locate, and identify clandestine nucleartests. It does this by providing detailed knowledgeof the earth’s structure and signal propagationcharacteristics developed at DOE’s national labs.

Sandia-developed information management sys-tems, applications interfaces, and user interfacesintegrate the Knowledge Base with the 24-hour-a-day operations at the NDC. (6500, 6100, 5700)Ralph Keyser, [email protected]

India and Pakistan have come together at theCooperative Monitoring Center (CMC) to collabo-rate on issues of common regional concern. ACMC-sponsored water quality project shared dataamong India, Pakistan, Nepal, Bangladesh, and SriLanka. Workshops at CMC and overseas wereconducted with the Department of State, StanfordUniversity, and the Regional Center for StrategicStudies on cooperative monitoring to enhanceregional security. Visiting scholars from India,Pakistan, and the US published papers on SouthAsian nuclear doctrines and agreements, potentialfor regional naval cooperation, and border secu-rity. (5300) Kent Biringer, [email protected]

The first in a series of Operation: Americatraining workshops for bomb squads was held inSan Diego, Calif., Sept. 18-22. The program focuseson advanced disablement technologies to render-safe complex terrorist type devices. Several morefive-day workshops are planned, each hosted by adifferent US city and involving bomb techs from

the neighboring region. The San Diego workshopwas hosted by the San Diego County SheriffsOffice and the US Navy and taught primarily bySandians. The Operation: America series is spon-sored by the National Institute of Justice. (5900)Chris Cherry, [email protected]

Mission Analysis and Simulation Dept. personneldeveloped an improved method for evaluatingthe performance of an inter-satellite communica-tions system used by the constellation of GlobalPositioning System (GPS) satellites. The method,while collecting large amounts of data without sig-nificantly impacting either space or ground opera-tions, provided new insights into possible errorsources. This in turn led to the development ofnew error reduction techniques, and subsequentlyinfluenced the design of future GPS satellites.(2600, 5700, 6500) Bill Richard, bdricha@ sandia.gov

Sandia has completed two projects demon-strating technologies vital to protection ofmajor US facilities against chemical and biologi-cal agent attacks. One project has deployedchemical agent detectors and supporting infor-mation systems into a testbed in the Washington,D.C., subway system to provide operational datathat addresses the long-term reliability and falsealarm characteristics of detection systems. A sec-ond project has focused on the release of tracersin the San Francisco International Airport tocharacterize attacks and to evaluate the potentialof air handler responses to mitigate effects. Bothprojects are sponsored by the DOE Chemical andBiological National Security Program. (8100,2200, 8900, 6400, 6200) Larry Brandt,[email protected]

A Chemical Defense Assessment Team wasformed at the direction of Gen. Eugene Habigerto study defenses against the possible use oflethal chemical agents to attack the peopleguarding SNM (Special Nuclear Material) at DOEsites. This Sandia-led team assessed three of themost critical sites this past year and wrote, withthe aid of experts from Sandia and DoD’s Edge-wood Chemical Biological Command, A Guide toDefending SNM Facilities Against ChemicalAttacks. (8100, 5800, 9100) John Vitko,[email protected]

Environmentalremediation

Under contract to DOE Nevada, wecompleted a Performance Assessment (PA)for disposal of transuranic wastes in aGreater Confinement Disposal (GCD) con-figuration at the Nevada Test Site (NTS).The assessment documents almost 10 yearsof site studies and system characterization;development and evaluation of conceptualand mathematical models and ranges ofdefensible input parameters; and finaldemonstration of compliance with Envi-ronmental Protection Agency standards.The PA easily demonstrated protection ofhumans and the environment, and thatGCD is an ideal system for isolatingradioactive wastes in arid settings such asthe NTS (6100, 6800). Doug Brosseau,[email protected]

Sandia’s Solid Waste Transfer Facilityteamed with Kirtland AFB to implement abase-wide residential recycling centerwhich achieved DoD recycling goals andnational recognition by winning the AirForce Materiel Command “Ronald YatesAward for Team Excellence.” Materialscollected at the recycling center includeplastic, aluminum, new paper, cardboard,tin, and glass. Further teaming efforts nowinclude pick-up of Kirtland’s commercialcardboard, roll-off truck services, and jointuse of equipment. (7100) Gabe King,[email protected]

First Solid State Ultraviolet Verti-cal Cavity Surface Emitting Laser (UV-VCSEL): Sandians and researchers atBrown University have used theresults of in situ stress studies to designan AlGaN/GaN distributed Braggreflector. This reflector enabled thefirst demonstration of an InGaN UV-VCSEL. These lasers will be part of arevolution in white lighting wherecurrent lighting will be replaced withsolid state lighting as envisioned inthe National Solid State Lighting Ini-tiative. The improved efficiency ofsolid state lighting will result in ahuge energy savings and pollutionreduction. (1100) Robert Biefeld,[email protected]

Sandia researchers, with industrypartners Cielo, Inc., have developed thefirst 1.3-micron electrically pumpedvertical cavity surface emitting laser(VCSEL) grown on gallium arsenide. The1.3-micron wavelength, which is opti-mal for ultra-high bandwidth data com-munication over glass fiber optics, isalso transparent to silicon, allowingconsiderable flexibility in incorporatingsuch a photonic device with siliconmicrosystem structures. (1700, 1100)Peter Esherick, [email protected]

Microelectronics

SANDIA SCIENTIST Jung Han adjusts laser pumping on a prototypeultraviolet VCSEL surface. (Photo by Randy Montoya)

Arms control(Continued from page 7)

CHRIS CHERRY, left, Sandia’s world-recognized bomb-disablement expert, demonstrates render-safe technol-ogy during last year’s Operation: America training work-shop for bomb squads from across the US. The 2000program was held in San Diego and was sponsored bythe National Institute of Justice.


Emerging threats

Reliable, autonomous mobility in difficult envi-ronments has previously eluded robotics engineers.Intelligent System Sensors & Controls Dept. 15211’sDARPA-funded work developed a hopping machinethat may soon give robots unprecedented mobilityfor exploring other planets, gathering war-fightingintelligence, and assisting police during standoff orsurveillance operations. Most mobile robots aredesigned to steer directly to a spot and requireexpensive and complicated control systems. Overlong distances you don’t need asmuch precision, so semi-randommobility is sufficient for many appli-cations. Jerry Langheim, [email protected]

Sandia-developed Rapid TerrainVisualization (RTV) InterferometricSynthetic Aperture Radar (IFSAR) is arevolutionary terrain-mappingradar capable of producing terrainelevation maps with height accura-cies of 0.5 m. The system providesthe Army a two-hours-to-data map-ping capability for regions of conflictand enables battlefield visualization.The system solves three key prob-lems in interferometric mapping: 1)timeliness of data through real-timeprocessing, 2) high-accuracy digital-elevation maps through innovativemultipath reduction techniques, and3) the elimination of phase unwrap-ping through multiple antenna base-lines. RTV is the first program todemonstrate these capabilities.(2300, 5900). Gene Kallenbach,[email protected]

Gathering andtransmitting measure-ments during explosiveevents is a difficult taskrequiring a broad radiofrequency bandwidth.We successfully flight-tested a 33 megabitsper second (Mbps), 16-symbol QuadratureAmplitude Modulation(QAM) High ExplosiveRadio Telemetry(HERT) that is designedto collect and trans-mit data during ahigh explosive deto-nation. The primarybenefit of QAM isbandwidth reduction:To transmit a 33 Mbpsrate, this system requires10 MHz bandwidthcompared to over 35MHz using conven-tional telemetry. (2600,8400) John Moser,jcmoser@ sandia.gov

The first Explo-sives Destruction Sys-tem (EDS) unit designed, fabricated, and quality-tested by Sandia for the US Army Non-StockpileChemical Materiel program closed out a campaignof engineering development tests carried out at theDefence Evaluation and Research Agency (DERA)facility in Porton Down, England. World War Ivintage mortar shells and artillery projectiles (7filled with phosgene and 12 with mustard) weredestroyed, as was a container filled with morethan a pound of Sarin nerve agent. The chemicalagents were consistently destroyed belowdetectable limits. (8100, 15300, 8700)Al McDonald, [email protected]

An advanced diagnostic tool, the line-imagingoptically recording velocity interferometer system(Line-ORVIS), has been developed and demon-strated, under LDRD funding, to quantify materialdynamic response at unprecedented temporal andspatial resolution. This diagnostic provides 1-D spa-tially- and temporally-resolved material responseand/or provides single-time 2-D response data. Line-Orvis has been applied in collaborative computa-tional “discovery” studies of energetic materialmechanical response at the meso-scale, has provideddata critical to stockpile materials, including PZT,ALOX, and HMX, and is a primary diagnostic forZ-pinch physics studies. (9100, 2500, 1600) ArthurRatzel, [email protected]

Following two years of planning and coordina-tion, a series of chem/bio simulant release tests were

performed at the San Francisco International Air-port. The simulated chem/bio agents werereleased to experimentally characterize the responseof the facility to a terrorist attack with theseweapons of mass destruction. The experimentswere a major milestone under the PROTECTDomestic Demonstration and Application Programfunded by DOE, which is intended to demonstratethat DOE technolo-gies can be success-fully used to addressthe emergingchem/bio threat tocritical national infra-structure. (9100,8100, 6400, 6200)Richard Griffith,[email protected]

We integratedand tested a fuel cellpower system on arobotic vehicle, an industry first. The fuel cell com-bines hydrogen and oxygen at low temperaturewithout combustion to produce electricity at highefficiency, potentially offering much greater opera-tional range than batteries presently used. In collab-oration with the Fuel Cell Propulsion Institute, San-dia combined an H-Power Corporation stack with ahydride bed hydrogen storage unit developed atSandia/California. (15200, 6200) Jerry Langheim,[email protected]

In July 2000, Sandia completedwork on two royalty-bearing licenseagreements to commercialize San-dia’s decontamination formulationfor chemical and biological weaponsagents. The formulation can bedeployed in various ways: as a foam,fog, spray, mist, or liquid. It is non-toxic to humans. The two separatelicensee companies obtained nonex-clusive rights under the agreementsthat allow them to supply emergencyresponders with technology that canmitigate the effects of a chemical orbiological attack. Part of the royaltyand fee revenues will support futureLabs R&D endeavors. (11500) RussellElliott, [email protected]

The Laser Dynamic RangeImager (LDRI) sensor was developedfor NASA/Johnson Spaceflight Center(JSC), which provided the funding forthis project. The LDRI sensor, capa-ble of capturing 3-D images at a rateof 7.5 Hz, was delivered to Kennedy

SYSTEMS RELIABILITY DEPT. 6411’s primary efforts during FY00 focused on the broadarea of sustainment and readiness of weapon systems. Major programs were establishedwith: Lockheed Martin in Support Enterprise Modeling and health monitoring for theJoint Strike Fighter and the F-16; Raytheon in Service Life Extension for the AdvancedCruise Missile and predictive reliability/maintenance for the Future Combat System;DARPA/Army in predictive reliability/maintenance and health monitoring for the Joint Vir-tual Battlespace; the Air Force in supply chain management and spares optimization forthe F-22; and the Army in predictive reliability and retrofit optimization for the Apachehelicopter. (6400) Jerry Langheim, [email protected]

Warbirds

ONLY A TEST — Chem/Bio Simulant Release Test in SFO Boarding Area G. The simulatedchem/bio agents were released to experimentally characterize the response of the facilityto a terrorist attack with these weapons of mass destruction. The tests were designed todemonstrate that DOE technologies can be successfully used to address the emergingchem/bio threat to critical national infrastructure. (Continued on next page)

ROBOTIC VEHICLEWITH FUEL CELL

HOPPER co-developer Barry Spletzer shows how high thenew hoppers can go. This one leaps 10-20 feet high oneach jump. (Photo by Randy Montoya)


Computing

Spaceflight Center in September and installed on the Endeavor space shuttle. Acritical demonstration of the sensor was completed successfully during a Novem-ber Shuttle mission. (2300, 5700, 9100, 14000, 15000) Jerry Langheim,[email protected]

The Short-Pulse Laser (SPL) Program made hallmark scientific discoveriesin FY00. World’s-first laser techniques for creation, sustainment, and control of 50femtosecond “optical bullets” were developed, world record propagation distanceswere achieved, and new phenomenologies were demonstrated in the lab and infield trials. These successes secured a combined DoD/DOE FY01 funding increaseof roughly 50 percent over FY00. The SPL team includes nationally recognizedexperts from Center 15300. Sandians from other divisions contribute to the pro-gram’s success on an as-needed basis. (15300) Jerry Langheim, [email protected]

The Information Design Assurance Red Team (IDART) has continued toanalyze advanced information systems for DARPA with the intent to helpdesigners rethink traditional system design approaches. Major accomplish-ments in FY00include the defini-tion and characteri-zation of adversarymodels that range insophistication fromnovice to foreignintelligence and thedevelopment of atraining curriculumin the IDARTmethodology. Theteam trained new“Red Teamers” atSandia and DARPA toanalyze systems froman adversarial pointof view to demon-strate how a cyber ter-rorist, for instance,might exploit vulner-abilities. (6500, 2600,5800, 9300) JerryLangheim,[email protected]

COMIN’ AT YOU — Sandia’s Information Design AssuranceRed Team, good guys playing bad guys, seeks out weak-nesses in computer systems. Red Team members shownare, at keyboard, David Duggan (6236), from left in thebackground, Michael Eckley (2662), Ruth Duggan, RayParks, Julie Bouchard (all 6237), and Dave Farrell (5932).

(Photo by Randy Montoya)

Emerging threats(Continued from preceding page)

The qualification of the MC4380 Neutron Generator was com-pleted for the W76-0 and a major corporate milestone was met. Thisproject showed for the first time that we can design and qualify a com-ponent to survive strategic radiation environments without under-ground testing. We also established a new Neutron Generator Produc-tion Facility and showed we can reliably produce neutron generatorsfor the stockpile. This project was accomplished through the team-work of organizations throughout Sandia. (2100, 1800, 2500, 2900,3500, 4600, 6200, 6400, 7100, 8400, 8500, 8900, 9100, 9200, 9500,9800, 10200, 12300, 14000, 15300) Pat Sena, [email protected]

The W76 Recertification Program was put on hold for six monthsto assist in the October 1999 deadline for the MC4380 Generator pro-duction. After coming back on line with full production of the recerti-fication program and with reinstated ship requirements, the programpicked up where it left off. We are now at 63 consecutive successfulQuality Assurance Inspection Process (QAIP) submittals to the DOE.The program continues to meet 100 percent of ship requirements tothe Navy. (9100, 2500, 141001, 14400, 10200) Norman Schwentor,[email protected]

A process has been researched and developed whereby micron-scale tools can be fabricated using a Focused Ion Beam. These toolsmay then be used on precision machining equipment to make micron-scale features. Previously, miniature machining techniques could onlyget down to the 50-100 microns scale. It is now possible to directlyfabricate micron-scale components out of traditional design materialssuch as stainless steel, alloys, and ceramics. We expect this technologyto have application in microactuation, microanalysis, medicine, andcomponent fabrication. (14100) David Adams, [email protected]

The Manufacturing Enterprise (ME) (14181/14186) was awarded aCertificate of Registration to ISO 9002 Quality Systems on April 28,2000. The ME is the first organization to achieve this recognition atSandia National Laboratories and a first for the DOE weapons labs. Itwas a process that began three years ago with a vision to position theME for the future. Accomplishing this task required major changes inour business processes, involved all aspects of our business and all ofour people. (14100, 12300) Paul McKey, [email protected]

Manufacturing & production

Cplant™, short for Computational Plant, isnow the largest Linux cluster in the world withnearly 2,000 Compaq Alpha nodes. The Cplantteam has developed a flexible architecture toaccommodate further additions, and a testingstrategy to ensure a production quality environ-ment for the users. In FY01, Cplant is to be a tri-Lab computing resource, extending its access tosister labs and to the open community. Cplantclusters have already reached usage levels up to90 percent. (9200, 9300) Neil Pundit, [email protected]

SecureNet Videoconferencing inProduction: A new, more reliable classified video-conferencing capability has gone into productionat Sandia/California and Sandia/New Mexico. Thesystem enables customers to use classified video-conferencing whenever they wish, without theneed to schedule through DOE/HQ. This video-conferencing capability uses the SecureNet net-work infrastructure to transport video and audiobetween sites. Interest in this new classifiedvideoconferencing system is spreading quicklythroughout DOE. (8900, 9300, 2100) Brian Cham-berlain, [email protected]

As users on the Sandia Restricted Network(SRN) have been keenly aware, network outagesover the past year or so have interrupted businessat very inopportune times. A year ago, networkreliability dropped below 99 percent, which wasunacceptable. A Network Reliability Task Forcewas assembled to analyze and address the prob-lem. In the first quarter of FY00, reliability was

99.3 percent, 99.5 percentthe 2nd quarter, 99.8 per-cent the 3rd quarter, and99.9 percent the 4thquarter. The team contin-ues to work towardimproved reliability andavailability, while sup-porting the dynamics ofadvanced systems thatsupport supercomputingusers and MESA. PatManke,[email protected]

The corporate needfor information manage-ment, retention, and col-laboration tools on boththe restricted and classi-fied networks was accom-plished with the imple-mentation of WebFileshare (WFS). Morethan 16,000 files havebeen contributed by usersat the Labs and 2,800searches are run eachmonth. This contentmanagement system pro-vides a common set oftools to effectively man-age information throughits life cycle — from cre-ation to archiving. It canbe integrated with projectWeb sites to assist inaccessing collections ofinformation. (9300, 9500,9600) Beth Moser,[email protected]

CHECKING OUT CPLANT™ — Carl Leishman (14111) examines one of many racks ofcomputers that, when clustered together, form the basis of Sandia’s CPlant system, thelargest Linux cluster in the world, with nearly 2,000 Compaq Alpha nodes.

(Photo by Randy Montoya)(Continued on next page)


Energy and criticalinfrastructure

After 10 years of planning, design, and con-struction, Sandia overpressurized a 1:4-scalemodel of a Japanese nuclear reactor pre-stressedconcrete containment vessel to failure. Themodel, tested for the US Nuclear RegulatoryCommission and Japan’s Nuclear Power ElectricCompany, initially leaked at 2.5 times the designpressure (Pd) before reaching a maximum pres-sure of 3.3 Pd. The data from almost 1,500 sen-sors will be used by an international team ofexperts as a benchmark for structural analysiscodes and will aid the development of new state-of-the art accident response models. (6400) MikeHessheimer, [email protected]

The safety of high-power lithium-ion batter-ies, which will be used in hybrid electric vehiclesand the NASA Space Shuttle, is of key impor-tance. Thermal runaway in lithium-ion cells, ifnot controlled, can have serious safety implica-tions. Our calorimetric studies have identifiedthe mechanism of thermal runaway underabuse conditions. This improved understandingof the reaction sequence will enable researchersto investigate the chemical mechanisms responsi-ble for thermal abuse intolerance, mitigate theseeffects, and substantially improve the operationalsafety of batteries for these applications. (2500,1800.) Dan Doughty, [email protected]

Risk Informed Regulation: Many existingregulations governing design and operation ofnuclear power plants in the US do not contributeto safety and reliability, which has resulted inunnecessary burden to plant operators and regu-lators. The Nuclear Regulatory Commission isusing risk-information to identify alternatives to

existing regulations. The first step established arisk-informed framework for generating alterna-tive regulations. The framework ensures thatnew regulations protect public health and safetyby providing defense-in-depth measures thataddress the prevention and mitigation of risk-significant accidents. (6400) Jeff LaChance,[email protected]

Severe AccidentAnalysis: Department6415 recently releasedversion 1.8.5 of the MEL-COR code, a software product developed for theNRC embodying more than 20 years of researchinto severe accident behavior. MELCOR modelsthe progression of a severe accident in a nuclearpower plant and potential release of fission prod-ucts from the site. A significant advance over pre-vious MELCOR releases, version 1.8.5 was distrib-uted to more than 40 foreign and domestic usersfor application to plant safety and licensing stud-ies around the world. (6400) Randy Gauntt,[email protected]

Sandia fire safety research contributes tosafer nuclear power plants and continues toreceive industry and customer praise. Notableaccomplishments this year under Nuclear Regula-tory Commission-sponsored programs include:assessing the impact of fire-induced cable faultson power, control, and instrument circuits;review of worldwide nuclear plant fire events; andplant fire safety inspections. These efforts are sup-porting development of risk-informed regulatorystandards and policy designed to maintain highlevels of safety while eliminating requirementsmarginal to risk. (6400). Steve Nowlen,[email protected]

Over the past two years, we have conductedan extremely aggressive Sandia-led project todevelop, integrate, and test a state-of-the-artdish/Stirling solar power generation system.We pulled together the “best-of-the-best”advanced technologies, and in November 1999,demonstrated unattended operation of the proto-type system. The system has met all of its perfor-mance objectives and demonstrated to DOE thatSandia is second to none in the integration ofsolar thermal systems. We will field a second-gen-eration system on an Indian reservation in theSouthwest next year. (6200) Richard B. Diver,[email protected]

The 2001 American Physical Society HerbertP. Broida Prize has been awarded to David W.Chandler, Sandia National Laboratories, and PaulL. Houston, Cornell University, “for their criticalcontributions to the investigation of vibrationallyand rotationally resolved molecular photodissoci-ation and reaction dynamics, in particular for theinvention and development of the photofrag-ment ion imaging method.” Ion imaging enablesstudies of the dynamics of photodissociationprocesses with a degree of detail unmatched byany other method. This technique has beenadopted by laboratories worldwide since the firstdemonstration in Dave’s lab in 1986. (8300) JohnGoldsmith, [email protected]

Each year US industries spend enormoussums ($1 million/yr at a typical oil refinery) com-batting gas leaks. To simplify leak detection,Sandia has developed a portable instrument thatmakes video movies of gas plumes. An infraredlaser illuminates the scene and the gas becomes

The Sandia Classified Network (SCN) re-emerged as an enhanced capability providingSandia engineers and scientists the requestedfunctionality and tailored security to accomplishtheir critical mission work. The solution cre-atively featured the flexibility of Web technolo-gies interwoven with unique need-to-know secu-rity structures. This achievement marks a majorstep in the alignment of IIS activities with majorSandia program focus. (IIS, 8900, 2900, 9800,9300) William Swartz, [email protected]

To increase user access and efficiency, morethan 1,000 journals are now provided electroni-cally to your desktop through the TechnicalLibrary’s full text, electronic delivery of informa-tion. The Engineering Index, SciSearch, SocialSciSearch, and INSPEC are examples of our subject-specific indexes, and electronic indexes are linkeddirectly to full-text articles. From the Library’sweb page you can also access electronic referencetools, like the CRC Handbook of Chemistry andPhysics. (9600) Lynn Kaczor, [email protected]

The cost of desktop computing support atSandia reached a new low of $2,200 annually percustomer in FY00 while adding several new ser-vices and achieving increased customer satisfac-tion (a new high of 8.8 on a scale of 10). This isa 31 percent reduction from 1994’s cost of$3,200 when the CSUs were first formed. Thereduction is the result of process and technologyimprovements implemented by Computer Sup-port Units, Technology Development, and theCorporate Computing Help Desk. Charles Shirley,[email protected]

Agile intrusion detection processes, new fire-wall management procedures, network scanning,switched high-speed networks, and the SandiaCommon Operating Environment have produced

a robust cyber security architecture that has with-stood the test of numerous audits and reviews.Viruses, various Internet attacks, attempted intru-sions, and unauthorized access are subject to rig-orous scrutiny and rapidly adjudicated whendetected. On-line procedures, rapid responseteams, and a sophisticated cyber architecturehave created a state-of-art system designed toprovide Sandia an effective cyber security pos-ture. (9300, 9600) R. Michael Cahoon,[email protected]

The Scalable Rendering Team developed ahigh-performance computer graphics render-ing system. The large ASCI (Accelerated StrategicComputing Initiative) supercomputers generatedatasets exceeding the capability of the largestcomputer graphics systems. The team used $350PC graphics cards to build a scalable renderingsystem. Recent results, using a 64-node graphicscluster, demonstrated rendering 225 million poly-gons/sec. This is 100 times faster than the bestgraphics pipe available on the production ASCIvisualization servers. This technology is a keycapability for the ASCI program. (9200).Phil Heermann, [email protected]

The Virtual Node Operating System (VNOS)Team extended the Cougar OS to enable userapplications to transparently access computecoprocessors on Sandia’s ASCI Red teraflopssupercomputer. This work was driven by theneeds of the Tflops user community for morecomputational throughput and by severe sched-ule constraints imposed by Sandia’s support con-tract with Intel. The team developed and deliv-ered the VNOS capability in six months. whilemeeting all of Intel’s stringent testing and evalu-ation requirements for the OS. The Virtual NodeOS provides the ASCI Red user community withthe equivalent of many thousands of hours ofadditional Tflops computer time, worth tens ofmillions of dollars, over the four years of themachine’s expected remaining life cycle. This isa high payoff for a project that cost less than$500,000. (9200) Robert Benner,[email protected]

Computing(Continued from preceding page)

QUARTER-SCALE prestressed concrete containment vessel,overpressurized to failure as part of a test conducted bySandia for the US Nuclear Regulatory Commission andJapanese nuclear power industry. (Photo by Randy Montoya)

USING THIS Sandia-developed portable instrument, aninfrared laser illuminates the scene and the gas leakbecomes “visible” by absorbing the laser light.



“visible” by absorbing thelaser light. The small sizewas enabled using newlydeveloped laser materialsand a high power fiberamplifier. The technologywill be tested at a refineryin April and is being evalu-ated by the EPA. (8300)Tom Kulp, [email protected]

New TechniqueReduces Well Failure Rate atCalifornia Diatomite OilFields: Rock compactionresulting from oil produc-tion can cause severe bore-hole damage, sometimesresulting in expensive wellabandonment and replace-ment drilling. Sandia scien-tists, with funding fromDOE, Chevron, and AeraEnergy, developed amethodology for understanding the failurepotential of wells in diatomite reservoirs. Theapproach used 3D coupled reservoir flow - geome-chanical simulations to predict the impact of dif-ferent well drilling patterns and water flooding

on well integrity in weak rock formations. Theindustry partners have incorporated the Sandiatechnique into their reservoir management prac-tices. (6100, 9100) Joanne Fredrich,[email protected]

Many Sandians have made significant contri-butions toward the completion of the YuccaMountain Site Recommendation ConsiderationReport. This report cumulates technical advance-ments in site characterization, performance assess-ment, and engineering design of Yucca Mountain.It will be given to the DOE Secretary for consid-eration in recommending Yucca Mountain as ageologic disposal site for high-level radioactivewaste. If the Secretary decides to recommendYucca Mountain as a suitable site, a Site Recom-mendation will be sent to the President in 2001.(6800, 6100) Hong-Nian Jow, [email protected]

A new way to safely, simply, and effectivelyconnect electricity-producing photovoltaic(PV) solar systems to utility company powergrids has been developed. Several manufacturershave adapted it into their systems. This Under-writers Laboratories-certified control methodautomatically diverts or turns off electricity flowfrom grid-connected PV systems when an electricdistribution line shuts down. Joe Tillerson,[email protected]

The Advanced Information System Lab (AISL)developed a radical and innovative new approach

to computer security. It uses intelligent agentsto implement a dynamic defense. It will havesignificant impact on Sandia’s national securitymission and commercial value to the multi-bil-lion-dollar cybersecurity industry. The research

team recognized theneed for a paradigmshift in informationsecurity practices tomeet the next genera-tion Internet securitythreats and developedStandard Agent Archi-tecture II (SAAII)/Agent-in-a-box, which incor-porates severaladvances in state-of-the-art agent and infor-mation securitydomains. This researchwas funded by LDRDand DP funds. Reynold

Tamashiro, rstamas.sandia.gov

Sandia recently completed a seminal report(NUREG/CR-6672) that provided much moreaccurate risk estimates of transporting spentnuclear fuel. The Sandia work is already beingused to revise theYucca MountainDraft EnvironmentalImpact Statementand will become acommon referencefor regulators, users,and the public. Bymatching accidentstatistics and accidentconditions, and mod-eling cask and fuelresponse to thoseaccident conditions,transportation acci-dent dose risks wereshown in NUREG/CR-6672 to be threeto four orders of mag-nitude smaller thanthose in NRC’s cur-rent EIS for radioac-tive material trans-portation(NUREG-0170),which demonstratesthat shipping spent

nuclear fuel is very safe.(6100) Ken B. Sorenson,[email protected]

Emissions of sulfurdioxide (SO2) from fossil-fuel combustion dominatethe atmospheric sulfur bud-get. In-situ SO2 measure-ments are required toaddress long-standinguncertainties about theinfluence of these emis-sions on local, regional,and global scales. Sandiaresearchers have recentlydeveloped a laser-induced-fluorescence detectionscheme for SO2 that hasthe requisite sensitivity(parts-per-trillion) for mea-surements throughout theatmosphere. They haveconstructed a prototypesensor, which has beenused for ambient SO2 mea-surements, and are devel-oping a compact ultravioletlaser system for use in fieldstudies. (8300) Dahv Kliner,[email protected]

Significant improve-ments have been made inour understanding of sootformation in dieselengines, the most efficient

engine option available for transportation.Research has demonstrated that the amount offuel-air premixing upstream of the initial flamelocation on a diesel spray plays a pivotal role inthe amount of soot formed. The research is pro-viding insight on how parameters such as injec-tion pressure, orifice diameter, turbocharging,intercooling, etc., impact the soot formation indiesel engines and suggesting directions for reduc-ing soot formation. (8300) Dennis Siebers,[email protected]

In October 2000, Sandia completed a two-yearproject with Lockheed Martin with the commis-sioning of a radioactive waste processing facility atthe Zvezdochka Shipyard in Severodvinsk, Russia.A similar facility will be commissioned in June2001 at the Zvezda Shipyard in Bolshoi Kamen,Russia. These facilities support Russian subma-rine dismantlement activities funded by the USDefense Threat Reduction Agency (DTRA). Sandiatechnical staff led the design, construction, andlicensing activities. Lockheed Martin EnergyTechnologies, the prime contractor for this DTRAproject, contacted Sandia in 1998 seeking its inter-national radioactive waste management experi-ence to accomplish this first-of-a-kind facility.(6800, 6400) Joe Jones, [email protected]

IN THE COUPLED MODEL, reservoir fluid pressures (P) as a function of space and timeare passed from the reservoir fluid flow simulation (left) to the geomechanical simula-tion (right). The oil reservoir sits within the central area (marked) of the finite elementmesh built for the JAS3D geomechanical simulations that consist of several hundredthousand elements.

Energy/criticalinfrastructure

SUB WORK — Sandians Joe Jones (6849, left) and Joe Saloio (5327, right) with OlegPazhukin of the Russian design institute VNIPIET near sorbent columns installed at the“Zvezdochka” Submarine Yard in Severodvinsk, Russia.

DISHING IT UP — Rich Diver (6216) checks out the first prototype of the 10kW Solar Dish/Stirling Remote PowerSystem, which incorporates the best of advanced solar technology developed at the Labs in recent years. A ver-sion of the solar collector will be placed on Indian lands in the Southwest where it will pump water for agricul-tural purposes. (Photo by Randy Montoya)

(Continued frompreceding page)


Labs SupportA Passport for the Journey: What do

you want to be when you grow up? Kidshear that question a lot, but have fewchances to explore different careers. Inresponse, Community Involvement joinedwith businesses, local government, andschool districts to provide the first annual“School to World” event. School toWorld provided 1,200 middle school stu-dents a chance to discuss more than a hun-dred careers with people who are actuallydoing them. In addition to funding andevent coordination, Sandia provided 65volunteers. (12600 coordinated) Amy Tapia,[email protected]

Sandia launched its first InformationTechnology/Computer Science (IT/CS)Retraining Program in June. Executive VP JoanWoodard and the Laboratory Leadership Team cham-pioned this Labs-wide, fast-track program that is led byCorporate Training and Development with partner-ships across the Labs. The program grew out of increaseddemands for critical IT/CS skills, hiring limitations, acompetitive external market, and Sandia’s commit-ment to career development. (3500, 6500, 8500, 9300)

Building Bridges, Sandia’s Participation inDOE’s EEO/Diversity Standdown, engaged morethan 8,000 participants in a forum for learningand dialogue on building inclusion, trust, andrespect in our work environments. Nearly 200 indi-viduals working in more than 20 sub-teams in NewMexico and California contributed to this Labs-wide effort. As a result of the program, suggestionswere produced for positive action to ensure goalsthat take full advantage of the diversity of peopleat Sandia. (3000, 8000)

Sandia/New Mexico Health Services Center’sClinical Health and Occupational Medicine organi-zations were recognized for quality programmingand services with five President’s Quality Awards,including three Golds. The Health Services Centerwas also awarded the highest level of accredita-tion by the Accreditation Association for Ambu-latory Health Care, Inc. (AAAHC). (3300)

The Benefits Department oversaw the renova-tion of the Bldg. 861 cafeteria. This cross-organi-zational project included both internal and exter-nal organizations for the design and completion.Construction was done in half the normal time

required for a project of this magnitude. Theupgrade ensures compliance with safety and coderequirements; reduces maintenance costs; creates amore efficient flow of traffic as requested by cus-tomers; improves the ambiance in the dining area,and increases the quality of time spent there.(3300, 7800, 7100)

Sandia hosted its Fifth Annual Summer Tech-nical Student Symposium and Career Fair onAugust 10 with 504 attendees, 150 presenters, and26 exhibitors. The symposium culminated a 12-week program for 250 technical interns at Sandia.The program provided technical and professionaldevelopment and required interns to preparepapers and presentations on assigned projects. TheSymposium offered an opportunity for Sandia andLockheed Martin, cosponsors of the event, to con-sider candidates for employment. (3500)

More than 100 women managers attended aone-day conference May 11 with the theme“Creating a Woman-Friendly Culture at Sandia.”Executive VP Joan Woodard and HR were confer-ence champions. The conference provided aforum to share experiences and make workplacerecommendations. More than 100 summer andyear-round interns attended Sandia’s first “Techni-cal Women of the Future” luncheon June 12.Speakers at the luncheon encouraged femaleinterns to continue their pursuit of higher educa-tion in science, math, engineering, and technol-ogy and provided an overview of Sandia’s philoso-phy and practices. (3000)

The FacilitiesCustodial ServicesDepartmentrolled out a new cleaning managementprocess in FY2000. This process has dra-matically increased building tenant sat-isfaction by improving cleanliness andefficiency while expanding the scope ofservices provided. The system is builtaround teams of specialists using moreeffective equipment and standard chemi-cals, and includes techniques for workloading and scheduling. The teamsshould be fully deployed during spring2001. (7800) James Kadlec,[email protected]

During FY00, the Facilities Manage-ment and Operations Center (withNuclear Weapons Strategic Business Unitfunding) demolished five buildings at

the New Mexico site. These demolitions elimi-nated more than 67,000 square feet of substandardspace. The demolition program reduces operationsand maintenance costs and allows building sites tobe re-used for new mission requirements. Duringthis same period, vacant space was reduced bysome 7,000 square feet. This increased efficiencyin the use of available space also reduces operatingcosts for the entire Labs. (7000) L. Patrick Murphy,[email protected]

The Processing and Environmental Technol-ogy Laboratory (PETL) received the Program andProject Management 2000 award from DOE’sOffice of Engineering and Construction Manage-ment. This achievement was made possible by thededicated efforts of many individuals who effec-tively teamed to construct this highly successfulfacility on schedule and within budget. The build-ing, now completely occupied, is a state-of-the-art21st-century materials science chemistry labora-tory that provides a safe, efficient (energy savingsof $100,000 per year), and attractive work environ-ment for its occupants. (1800, 7800) Bill Hendrick,[email protected]

In FY00, Sandia made significant strides inresource conservation:

• Earned two State Environment DepartmentGreen Zia awards for efforts to reduce energy andwater use at the central steam plant and incorpo-rate sustainable design into new building designs.

• Saved 22 million gallons of groundwater by

Sandia’s Security Police Facility Com-mand Center (FCC) became operational lastApril in a newly constructed, modernized areain Bldg. 956. It has state-of-the-art phone andradio systems, caller ID, and 911 tie-in. The newstrategic location saves officers’ time and trans-portation costs. Our old Headquarters Com-mand Center in Bldg. 802 (unstaffed, but fullyfunctional) is now the backup command center.No communications between Bldgs. 802 and956 existed before installation of a fiber-opticpathway. (7100, 7800, 9300, 9500) Janet Ahrens,[email protected]

All Security audits and surveys received sat-isfactory ratings (DOE’s highest ranking).Results noted Sandia has made significantprogress over the past year in improving andstrengthening the overall performance of theSafeguards and Security Program. In additionSandia made notable progress in implementingthe Energy Secretary’s new security enhance-ments. Enhanced security procedures for vaultsand vault-type-rooms were implemented.Unapproved space-savers were replaced withGSA-approved safes. Nonstandard storage loca-tions are either manned or alarmed. (7100) TerriLovato, [email protected]

More than 10,000 employees and con-

tractors, along with 4,000 visitors, wererebadged between April and June (mandatedby DOE and conducted every five years). Allreceived the newly designed DOE/Sandia stan-dard badge. In connection with rebadging, allLimited Area entrances at Sandia/New Mexicowere changed to require use of both badge andPersonal Identification Number. Thesechanges were accomplished with minimal dis-ruption to the Lab. Personnel Security alsoissued the newly designed ES&H Quick Refer-ence Card to more than 10,000 employees andcontractors. (7100, 7800) Bob Baca,[email protected]

A diverse multi-department team packagedand shipped enriched uranium to the Y-12Plant, reducing security risk and future costs.This multifaceted project presented a broadrange of new challenges, each requiring resolu-tion before work could begin. Concerted effortsof 40 individuals in 13 departments across threecenters were necessary to plan, execute, andfinalize the shipment. The synergy that evolvedwithin the team was paramount to success. Thecorporate knowledge gained here will facilitatecontinued initiatives to deal appropriately withSandia’s legacy nuclear material in coming years. (7100, 10200, 6400) Warren Strong, [email protected]

The College Cyber Defenders Program(CCD) provides students with hands-on experi-ence in the areas of information protection,computer security, networking, and distributedsystems. The mentors and staff of the CCD pro-gram have developed a unique environmentthat challenges students with cutting edgeresearch projects, while supplying multiple lev-els of new skills for students with varied com-puter backgrounds. The program has grownrapidly since its inception and has graduatedtwo students to full time jobs at Sandia. CCDstudents assisted in the December 1999 securityaudits. Nina Berry, [email protected]

The US Air Force installation in Izmir,Turkey, is distributed throughout the city in var-ious facilities, sometimes sharing the structureswith non-US businesses (hotels, etc). The terror-ist threat, at times, is real and imminent. Forthis nontraditional security application, Sandiahas provided and installed for the Air Forcean intrusion detection and surveillance capa-bility to deter and detect intrusions and otheractivities that could preface a terrorist incident.Part of this system is now used as a model for aEuropean-wide upgrade to the Joint ServicesInterior Intrusion Detection system. (5800) BobGraham, [email protected]

Security and force protection


Sandians and students at the first-ever “School to World” event.


Labs support

reusing microelectronics wastewater forother operations at Bldg. 858.

• Made the case for Sandia to purchase“green electricity” beginning FY01. (5300,6200, 7100, 7800) Ralph Wrons,[email protected]

Facilities Management & OperationsCenter implemented a major change lastyear by establishing a swing shift of fivemechanical tradesmen to perform pre-ventive maintenance. This breakthroughaction accomplished key objectives: mini-mizing disruptions to building residents;taking a proactive approach to reducemaintenance costs by significantly increas-ing preventive maintenance activities, thusreducing equipment failures; and, reducingovertime costs some $50,000 per year.(7800) James L. Rush, [email protected]

Facilities Management and otherexemplary operations at the California site com-pleted the demolition of the 85,000 sq. ft. Bldg913 to provide a building site for the new Distrib-uted Information Systems Laboratory. This was thelargest deconstruction project in the history ofSandia. Following a difficult relocation plan,approximately 20 functions were relocated into 10other existing facilities. With known building con-tamination the project team had to perform exten-sive and creative characterization and cleanup priorto demolition. The project recycled 6,500 tons ofconcrete and approximately two million pounds ofmetals (steel, copper, aluminum, brass). (8500)Gary Shamber, [email protected]

A project that involved everyone at Sandia?Yes, Sandians and contractors working at the indi-vidual, team, Labs-wide, community, and nationallevels assured that the Y2K transition was a non-event. Thousands of hours were spent identifyingand evaluating potential vulnerabilities of software,hardware, facilities, operations, & safety and secu-rity systems. The success of this project is a tributeto all who demonstrated true teamwork, thorough-ness of execution, and dedication. Participants rep-resent every organization in the company, theirDOE & LMC counterparts, and staff at the KAFB.(7000) Nancy Freshour, [email protected]

Sandia received several awards in recognitionof its outstanding achievement in providing con-tracting opportunities to small business and itsexemplary outreach activities. These awardsinclude: DOE’s Management and Operating Con-tractor of the Year Award, the U.S. Small BusinessAdministration’s Dwight Eisenhower Award forExcellence, the Southwest Region Business Advo-cate of the Year Award, and the District II Corpo-rate Hispanic Advocate of the Year Award. (10200)Cynthia Schneeberger, [email protected]

Oracle ERP implemented and stabilized:Sandia’s Oracle ERP system was stabilized aftercoming fully on line in October 1999. Included inthe implementation and stabilization wereimproved response times, development of substan-tial additional reports for line customers, ongoingtraining programs, and accomplishing the firstyear-end closing using the Oracle system. (9500,10200, 10300, 10500,14000) Cynthia Schneeberger,[email protected]

Pension plan benefits were approved thatincreased income for retirees and surviving spouseseffective Oct. 1, 2000. The benefit changesincluded increases in pension benefits from 3 per-cent to 18 percent for eligible participants and theintroduction of minimum pensions. (3500, 10300)Cynthia Schneeberger, [email protected]

Sandia’s Legal, Procurement, and HR organiza-

tions worked with Sandia Staff Augmentation sup-pliers to develop and implement an alternativeto the three-year rule which had previously lim-ited contract associates’ service to a maximum ofthree years. The alternative manages co-employ-ment risks in an innovative manner, enabling San-dia to retain the services of more than 425 trainedand valued individuals. These people would havehad to be replaced, increasing overall costs andreducing productivity. Instead, they can remain atSandia. (3500, 8500, 10200, 11200) Skip Reeder,[email protected]

Logistics developed a cost-effective way tomeet DOE regulatory requirements for on-sitetransportation of hazards. It consolidated opera-tions teams involved in hazardous material storageand transportation in one location and com-menced cross training. It excelled in numerousaudits, most notably an audit of Shipping and theFederal Motor Carrier Program by the Departmentof Transportation. It reduced the amount of timerequired for hazmat training certification andformed the Packaging and Transportation Manage-ment Committee to leverage corporate resources.(10200) Bob Eldredge, [email protected]

A team led by the Export Control Officeobtained funding from DOE/DP and completeddesign, development, and roll out of an on-linetraining program called EC100. This modularsystem automatically tailors the depth and breadthof the training to be taken based on the student’sresponses to an initial set of eight questions.EC100 has been completed by more than 250 peo-ple at Sandia, and has been requested by DOE andDoD as a model for next-generation training tools.(2900, 3500, 9500, 10000, 10300) Chad Twitchell,[email protected]

Sandia received DOE approval to make sev-eral significant computer codes available underopen source licensing. Open source licensing, usedfor common software packages such as Linux,allows a broad community of researchers to use,improve, and share improvements to software.Open source licensing will help transfer importanttechnology from Sandia, and will allow Sandia toleverage the efforts of others in improving technol-ogy important to our mission. The codes currentlyapproved for open source licensing include Cplant,Zoltan, Chaco, and Verde. (9200, 11500, 1300) V.Gerald Grafe, [email protected]

Sandia’s Legal Division supported the Con-tracts Organization in another successful effort toexecute a “fee and scope” amendment to ourprime contract. The amendment enables a stableflow of fee to Sandia, which is used to compen-sate our corporate parent for its contributions tothe Sandia mission, and to pay for expenses and

costs of Sandia, which are either “unal-lowable” under our prime contract orwould be viewed by DOE as either exces-sive or unnecessary. (11200, 10000) L. S.Greher, [email protected]

For 2000, the National AtomicMuseum increased children coming toacclaimed Science is Everywhere Sum-mer Camp from 80 in 1999 to 160 chil-dren in 2000. For 2001, the camps willincrease again and offer second site ser-vices at the Hispanic Cultural Center. Inaddition, the museum served 18,569school children with six educationalprograms for ages K-12. The museumpresented three programs called “YoungWomen Take Flight” to accompany aSmithsonian exhibition, Women inFlight, which was at the museumJanuary to May 2000. James Walther,[email protected]

In strategic planning, the LaboratoryLeadership Team refined the vision forthe Laboratories developed 10 yearsago, including revised values, revisedpurpose, and a new “highest goal.” Tostudy the long-term external environ-ment, LLT also developed scenarios forthe future, following the approach devel-

oped by Global Business Network. The four scenar-ios show plausible futures that the Labs could finditself dealing with in 15 years. Planning activitiesthis year will challenge program managers todevelop robust strategies for success in each of thescenarios. (12100) Lori Parrott, [email protected]

The Congressional Testimonies Team preparedseven congressional testimonies in FY00 — nearlytriple that of any previous year. The testimonieshave created or enhanced relationships with keystaffers and lawmakers in Congress. The integrity,candor, and responsiveness of the testimonies andwritten statements have improved congressionalperceptions of the Labs. (12100)

The Government Relations team, workingthrough the SBUs/SMUs, developed a Congres-sional Issues Document that contains a set of well-defined, prioritized issues whose resolution are crit-ical to Sandia’s success. The document contributessignificantly to conveying a uniform, consistentLaboratory message that has already been demon-strated to be effective. In concert, they developed aWashington strategy that will ensure that Sandia isproperly positioned to help shape the resolution ofissues of importance to national security. (12100)

The Ombuds team has intervened on contrac-tor dispute issues, diversity issues across the com-plex, and nearly 600 cases involving individualswithin the Labs. The Ombuds team interactswith all Sandians to ensure common understand-ing of differences and to provide a basis for disputeresolution. It is recognized across the DOE com-plex as a model program for excellence and isrepeatedly called on by DOE at all levels to assist indeveloping approaches for dispute resolution.(00011 and 00012)

The President’s Quality Award team serves a cor-porate strategy to target project teams for self-assess-ment and review of processes and customer relation-ships. This year, the number of applicationsincreased 40 percent over last year and a record ofnine gold awards was obtained. The PQA programreceived two international awards for its promo-tional videos. This year, the ceremony was aired liveand sent electronically to a total of 700 participants.(12100)

The Trades Training Program (TTP) is oper-ated by Sandia in cooperation with the Metal TradesCouncil, Albuquerque TVI, and Albuquerque Pub-lic Schools (APS). Attrition in Sandia’s skilled Tradesstrategic workforce is affecting product realizationcapabilities. The TTP aims to maximize use of com-munity resources, existing Sandia programs, and anew approach to training that produces fully quali-fied trades people at greatly reduced cost. (14100,3500, MTC) Phillip Gallegos, [email protected]

Sandia employees made a difference in their community once again. More than300 Sandia employees, contractors, family members, and friends, partneredwith retiree Irv Hall and Judy and Ronald Ewing to build a Habitat for Humanityhouse. Irv Hall (above) donated the $30,000, the Ewings donated the land,and Sandia volunteers pounded nails, hung wallboard, textured, painted, hadfun, and completed the house in seven working weeks. Others donated lunchesand snacks or contributed to the Carpenter’s Fund. The Zozaya family calls HallHouse home. (Photo by Randy Montoya)


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