2006 Labs Accomplishments

AAccccoo

mmpplliisshh

mmeennttss

AAccccoo

mmpplliisshh

mmeennttss

2200006622000066FFeebbrruuaarryy •• 22000066

THE LITTLE ROBOT THAT COULD . . .Meet the Sandia robot that helpedsecure a radiation source at White

Sands Missile Range. Details on page 5.

LLaabbss

LLaabbss

Sand

ia N

atio

nalL

abor

ator

ies

Welcome to this year’s edition of the annualLab News Labs Accomplishments.

Throughout this 16-page document, you’ll find aresounding affirmation of the depth and breadth ofSandia’s research and development capabilities —and a reminder that our people are the very best at

what they do.

It has been my privi-lege to lead this labo-ratory over the pastyear and to share withmany distinguishedvisitors, including thePresident of theUnited States, the evi-dent passion thatexists here for theimportant work we arecharged to do. As Iwalk through and flyto our facilities and

interact with our colleagues, I find that passioneverywhere; I believe it is one of the distinguishingcharacteristics of our workforce.

From crucial milestones met in our key missionareas to fundamental insights gained via our own dis-cretionary Laboratory Directed Research and Develop-ment program, this Labs Accomplishments issuedemonstrates that we are fulfilling the charge — withgusto — that underpins our approach to our work: “Toprovide exceptional service in the national interest.”

Tom Hunter, Sandia Laboratories Director In the first quarter of each calendar year the Lab News

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

For information about how to contact the researchersinvolved in the work mentioned here, e-mail Lab News staffmember Bill Murphy at [email protected].

Tom Hunter

To all Sandians:

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

http://www.sandia.gov/LabNews

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

Carlsbad, New Mexico • Washington, D.C.

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

Advanced concepts . . . . . . . . . . . . . . 5

Computing . . . . . . . . . . . . . . . . . . . . .6

Homeland security . . . . . . . . . . . . . . . 7

Defense systems and assessments . . . 8

Materials, chemistry, physics . . . . . . . 9

Microsystems . . . . . . . . . . . . . . . . . . .9

Engineering sciences . . . . . . . . . . . . 10

Biotechnology/nanotechnology . . . . 10

ES&H . . . . . . . . . . . . . . . . . . . . . . . 10

Energy, security, anddefense technologies . . . . . . . . . . .11

Nonproliferation . . . . . . . . . . . . . . . .12

Electronics . . . . . . . . . . . . . . . . . . . . 13

Pulsed power . . . . . . . . . . . . . . . . . . 13

Technology partnerships . . . . . . . . . .14

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

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

Sandia National Laboratories • Sandia Lab News

Ken Frazier • EditorBill Murphy • Labs Accomplishments coordinator

Inside . . .

ON A DAY that Sandia Labs Director Tom Hunter called “the most terrific day in our history,”President George W. Bush chose Sandia National Laboratories in Albuquerque as the venue tosign the Energy Policy Act of 2005. The landmark bipartisan legislation, sweeping in its scope,includes provisions to boost alternative energy R&D, nuclear energy, clean coal technologies, andmodernized energy infrastructure. In the photo above, Tom discusses a Sandia solar energy pro-

ject with President Bush, Secretary of Energy Samuel Bodman, US Sen. Pete Domenici, US Sen.Jeff Bingaman, and Sandia engineer Chuck Andraka (6218). During remarks prior to signing thelegislation, President Bush praised Senators Domenici and Bingaman, along with Texas Rep. JoeBarton, for representing “bipartisanship at its best” in shepherding the complex legislationthrough the labyrinthian Congressional process. (Photo by Randy Montoya)

Cover photograph byRandy Montoya

ALEGRA CODE used in armor penetration studies.

SANDIA’S THUNDERBIRD CLUSTER requires clusters of cabling.

(Continued on next page)

Sandia’s Red Storm computer metthree Advanced Strategic Computingmilestones last September and ran sev-

eral simulation problems never previouslypossible. Analysts from Sandia, Los Alamos,and Lawrence Livermore national labsdemonstrated the scalability of the system,using 5,400 to 7,200 processors, producingfirst-of-their-kind details in simulations offire, polar atmospheric phenomena, anddestruction of an asteroid in deep space.Teaming with Los Alamos and LawrenceLivermore researchers, we demonstratedplatform stability and user-environmentfunctionality and produced unique visual-ization results from these large runs on RedStorm. (4300, 1400, 1500, 1900, 8900)

Measurements of transient neutron dam-age have been made at the Los AlamosNeutron Science Center spallation neutronsource at times as early as 8 µs. The previ-ous record had been about ~250 µs for datagathered at fast-burst reactors. Observingthe early neutron damage is critical tofinding ways to certify Sandia componentsto weapon radiation requirements withoutthe use of fast-pulsed reactors such as theSandia Pulsed Reactor (SPR). The use ofsuch reactors is being curtailed due to secu-rity concerns about protection of specialnuclear materials.

Center 1700 delivered the proof-of-designmultiprogram application-specific inte-grated circuit (MPA) for the concurrentdesign/manufacturing program in a recordsix-and-a-half months. The MPA wasdesigned, simulated, verified, and laid-out in four months. The first fabricationlot was processed in our MicroelectronicsDevelopment Laboratory in a record eightweeks. The test program was completed infive days, with first silicon yielding 71 per-cent (2,000 parts). Fully functional partswere packaged in-house, tested across tem-perature/voltage, and delivered to the cus-tomer in October 2005.

Centers 2700 and 2900 used Lean/Six Sigma processimprovement techniques to streamline the engineeringchange order process for neutron generators. The processflow was reduced from 58 to 10 steps, reducing cycle timeby 20 percent, virtually eliminating rework, and reducingaverage processing time from 33 days to two-and-a-halfdays. The net impact represents an annual savings of$38,000, increased capacity, and significant gains in cus-tomer satisfaction. (2900, 2700)

We have completed a four-year, $10 million project to re-establish the Light Initiated High Explosive (LIHE) facilityand test capability at Sandia. Using remotely spray-painted,light-sensitive high-explosive applied directly to a test unit(to simulate an exoatmospheric cold X-ray hostile shockenvironment) the facility will provide validation data to sup-port the Science Based Engineering & Technology conceptsof rigid body mechanics, deformable mechanics, and ther-

mal-structural response.These models will be usedin the hostile-environ-ment qualification ofnuclear weapons systems.(2500, 2100, 10300,10800)

The B61-11 team devel-oped and executed anew Type 6C test con-figuration as a cable pull-down unit at Sandia’sAerial Cable Facility. Thiswas the first fully score-able surveillance test of aB61-11 using the facilityand was performed inlieu of a flight test atTonopah Test Range. Byclosely controlling theimpact conditions duringtesting, this new surveil-lance capability allowsfor worst-case testing ofthe B61-11 never beforeachievable through stan-dard flight testing. (2900,1500, 2100, 12300,LANL, KCP, BWXT)

Very high voltages can be produced by passing a shockwave through properly prepared (“poled”) lead zirconatetitanate (PZT) “active ceramic” material. Sandia neutrongenerator production requires a special PZT chemistry notcommercially available. To meet this need, a new solutionchemistry PZT powder synthesis process was developedand patented. Production-scale batches of PZT have beenprepared, and parts have been qualified to full weaponrequirements. These successes build on years of collabora-tive development work to optimize PZT chemistry, powdersynthesis, sintering procedures, and component fabrica-tion. (2400, 2500, 1800)

An 18-month New Mexico/California design competitionwas launched in May 2005 for a Reliable ReplacementWarhead for use in Navy and Air Force ballistic missileconfigurations. The goals: preserve military effectiveness,provide greater design margins, assure cross-platform com-patibility, and integrate surety options that enhance stock-pile security and eliminate nuclear safety exceptions, whilesimultaneously incorporating process and cost-controlimprovements across the weapons complex. (2100, 8200)

The W76-1/Mk4A design definition continued to mature,with reentry body and arming, fuzing, and firing sys-tems attaining Final Design Reviews. System qualifica-tion activities included successful testing for blast, impulse,abnormal thermal and mechanical, radiation, electromag-netic, and normal transportation environments. Four reen-try bodies that included a fully functional AF&F and newJoint Test Assembly were assembled and delivered to the

Navy for flight testing in early FY06. Theprogram received unconditional approvalfrom NNSA to proceed to ProductionEngineering Phase 6.4. (2100, 1700, 1800,5300, 2500, 2600, 2900, 8200, 1500, 12300)

The W76-1/Mk4A Life Extension Program(LEP) successfully flew four test bodieson the submarine-launched ballistic mis-sile Follow-On Commanders EvaluationTest (FCET-32). This test included severalimportant firsts: integration of the W76-1/Mk4A Reentry Body Assembly to a D5missile; flight of the Sandia-designedMC4700 Arming, Fuzing, and Firing sub-systems; and demonstration of the Sandia-designed telemetry package on the JointTest Assembly (JTA1). This major programmilestone is a critical element of the over-all W76-1 LEP and builds significant confi-dence with our DoD/Navy customer.(2100, 1500, 2500, 2600, 5300, 8200)

We undertook an aggressive program toreplace aging field test neutrongenerators by the end of July 2005. Neu-tron generators have a finite life, and newhardware was required to maintain thecapability — if ordered — of returning tounderground nuclear testing, a nationalreadiness requirement. Many technicalissues had to be resolved to manufacturethis reliable neutron source for theNational Test Readiness program. The pro-gram exercised our design capability andvalidated our manufacturing capability toproduce the higher-output, electronic,variable-timing, field test neutron genera-tor. The final two neutron generators werequalified through environmental testingon July 30, 2005, allowing Sandia todeliver nine generators, against the eightrequired. (2500, 2400, 5100)

The High Accuracy Sensor Package(HASP) successfully flew on a W87 JTA4

MK21 flight launched from VandenbergAFB in California last September. The Flight

Test Unit (see insetimage) was deployedfrom a MinutemanIII and impacted nearthe Ronald ReaganBallistic MissileDefense Test Site onthe Kwajalein Atollin the Pacific. HASPfeatures a high-per-formance, small-vol-ume inertial sensorpackage measuringreentry vehicle flightdynamics throughboost, separation,coast, and reentry phases. The package has better perfor-mance in half the volume of earlier generations. (5300, 8200)

Our thermal battery production team successfully submit-ted new, Sandia-fabricated Joint Test Assembly teleme-try batteries to NNSA in support of directive schedulerequirements. This production run was the first diamond-stamped lot fabricated entirely in Sandia dry room facilitiesfollowing the loss of a major thermal battery supplier in2004. A dedicated team of personnel procured tooling,qualified processes, and completed fabrication, inspection,and testing of the lot in less than half the time normallyallotted for a typical thermal battery production run.(2500, 1800, 2700, 12300)

Labs Accomplishments • February 2006

Nuclear weapons

IRRADIATIONS AT CRYOGENIC TEMPERATURES using liquid helium cooling have been conducted at fast burst reactors, spal-lation neutron sources, ion beams, and pulsed gamma sources to slow down damage annealing and permit a detailed investi-gation of early-time defect annealing as the temperature is slowly brought up to 300K. These studies support the Qualifica-tion Alternatives to SPR-III (QASPR) program and are designed to provide data supporting first-principles modeling ofearly-time damage annealing. The goal is to permit calculations and experiments at pulsed simulation facilities to replace theneed for fast-burst reactor testing.

Red Storm

B61 pull-down test atAerial Cable Facility.

Integrated Stockpile Evaluation (ISE) is a transformationinitiative that aims to integrate and transform the pro-grams and activities used to evaluate the US nuclearweapons stockpile. Key objectives include strengtheningour knowledge of and confidence in the stockpile, whilesignificantly increasing the cost-effectiveness and respon-siveness of the stockpile evaluation program. ISE accom-plishments during the past year include overall transforma-tion planning in conjunction with the NNSA StockpileEvaluation Transformation Leadership Team, the develop-ment of an alternative stockpile evaluation sampling ratio-nale, and the formation of Technical Basis RealizationTeams to develop the stockpile evaluation requirements forthe future. (2900, 2100, 8200, 12300)

In December 2004, following a complex-wide cost study,NNSA assigned the neutron tube target-loading mission toSandia. A finding of no significant environmental impactwas issued in June 2005. Cost projections indicated a greaterthan $5 million cost decrease, largely enabled by successesin Neutron Generator Production’s Lean/Six Sigmaprocesses. Target-loading consolidates neutron generationproduction at Sandia, resulting in a 60-day decrease of neu-tron tube production time. Target-loading with deuteriumis now fully operational in Bldg. 870 and will be an integralpart of production by the end of February 2006. (2700)

The MC4300 Neutron Generator Product Realization Teamis modeling the concurrent engineering practices advocatedin Technical Business Practices-Product Realization Process.Members of the design and production agencies have co-located, providing seamless cooperation and promotingdesign for manufacturability using Lean/Six Sigma andmistake-proofing principles. This effort has resulted in anestimated 30 percent (i.e. $10,000 per unit) cost reduction ofthe MC4300 neutron tube as compared to its predecessor.Recent yields have already surpassed those for the previousunit. (2700, 2500)

Sandia production delivered more than 7,300 components

to customers, including the success-ful submission of new thermal bat-teries to NNSA (the first diamond-stamped lot fabricated entirely atSandia — see entry above). Produc-tion includes 6,868 ConcurrentDesign and Manufacturing compo-nents, 299 neutron generators, and168 neutron generator packagingkits in support of the Navy, AirForce, other weapons complex pro-duction agencies, and the UnitedKingdom. An on-time delivery per-centage of 100 percent was achievedfor these products, which support allweapon systems in the stockpile.(1700, 2100, 2500, 2600, 2700)

We used W78 Modeling Pro/Engineermechanical design software to gener-ate highly detailed solid models ofthe entire W78 war reserve and jointtest assembly mid-section assemblies.These models accurately represent thegeometry and mass properties of everycomponent and follow Sandia’s mate-rial list structure exactly. The modelswere ultimately translated into a vir-tual reality environment for analysis,which made possible a far more accu-rate W78 use-control assessment thanwould otherwise have been possible.(2900, 12300)

DOE’s Office of Security and Safety Performance Assess-ment has assigned Sandia’s Protective Force ComponentTesting and Development Team to assess, develop, andimprove capabilities of our protective forces to withstandpotential terrorist attacks against the nuclear weaponscomplex. During the past year, the team has developed anew armored vehicle with a remotely operated weaponsystem and an “augmented reality” system to improvetraining effectiveness. The team has also made strides inmechanical breaching, a new multirole weapon system,and testing and evaluation weapon capabilities to breachsecurity fencing and penetrate hardened adversary assets.

The new Stockpile Dismantlement Database System is nowavailable on-line through the NWie on the Sandia Clas-sified Network and can be accessed ultra-securely by othernuclear weapons complex sites. This web-based Java appli-cation provides users an easier-to-use interface and betterreporting capabilities in support of nuclear weapons dis-mantlement activities. The successful deployment of thissystem met an NNSA Level II Milestone. (4500, 2900)

A novel Chemical Imaging Precision Mass Analyzer(ChIPMA), developed by Sean Maharrey (8300), RichardBehrens (8300), and Robert Bastasz (8756), is the first of itskind to couple ion beam and laser surface probes to ahigh-performance Fourier Transform ion cyclotron reso-nance mass spectrometer. ChIPMA uses the AXSIA imageanalysis package, developed by Mike Keenan (2400) andPaul Kotula (1800), to chemically map complex materials.As recognized by a DOE/DP Award of Excellence, ChIPMAis uniquely suited to understanding the long-term reactionprocesses that affect the safety, aging, and performance ofnuclear weapons components.

We successfully developed an aluminum-resist substratefor improved yield and new capabilities in metal microfab-rication by LIGA (X-ray lithography, electroforming, andmolding). By reducing secondary radiation during X-rayexposure, this low-z substrate eliminates delamination ofthe X-ray resist, reduces small-feature loss, and improvesdimensional accuracy. Through use of this substrate, wedemonstrated process yields near 90 percent and newcapabilities to fabricate isolated features as small as 5 µmand feature aspect ratios up to about 300. These are thelargest feature aspect ratios ever produced by LIGA. (8700)

Engineering Design Services Dept. 8948 joined with Dept.2990 and the Kansas City Plant in a tri-site joint valuestream mapping effort to identify and streamline the engi-neering authorization process in the nuclear weapons com-plex. Agreements and changes are being implemented thatwill shorten the process to one-to-three days. In relatedactivity, we organized and presented three sessions last year(two at the end of June and one in August) of a mandatoryengineering authorization training class for all individualsinvolved with the engineering authorization process.

The ability to positively secure high-value, high-conse-quence materials is essential. The Integrated Surety Solu-tions/End-to-End Command and Control demonstrationshowed the integration of critical technologies for thesecure transport of these materials while retaining posi-tive control. The demonstration was carried out by the2005 California weapon interns and members of the W84and Advanced Systems Dept. 8222 and Surety Design Engi-neering Dept. 8226. Various scenarios were explored anddemonstrated, validating that positive control over materi-als can be assured with minimum risk and interference toauthorized users. (8200)


Nuclear weapons(Continued from preceding page)


Hostile blast testing for the W76-1 Life Extension Program was completed inFY05. This is the culmination of a three-year testing and analysis programdesigned to ensure that redesigned components will survive an endoatmos-pheric nuclear blast from an adversary weapon. This effort tapped a broadrange of Sandia’s modeling capabilities, including codes CTH, SACCARA, andSalinas. Additionally, the uncertainty and repeatability of the blast tube envi-ronment was statistically characterized for the first time. The data and uncer-tainty bounds will be used to validate the computational model of the systemresponse. (2100, 1500)

THE FIRST W80-3 ENVIRONMENTAL FREE FLIGHT TEST was conducted at theUtah Test and Training Range in September 2005. The test unit, installed in anadvanced cruise missile, was launched from a B-52H aircraft and flew, asplanned, for some five hours. Flight environments (vibration, thermal, andacoustics) were collected and transmitted by the onboard telemetry system. Theinformation will be used to update the stockpile-to-target sequence and theW80-3 environmental specification. Center 8200 designed and built the datatelemetry equipment, and coordinated the flight test activities with the Air Force.

HELPING TRANSFORM the nuclear weapons complex byproviding lower-cost, rapid response parts for weaponsystems, the War Reserve COTS Insertion Process projectimplemented new processes and procured the latest-tech-nology, commercial-off-the-shelf parts for the W76-1 andW80-3. The project integrated design agency, productionagency, and third-party test houses into a virtual corpora-tion with test and part data trackers, and automatedworkflow. More than 400 of the approximately 500 life-of-program-buy part types (involving some two millionparts) were procured, saving more than $100 million onlife-of-program costs. (1700, KCP)

COTS comes through

Surviving endoatmospheric attack

MODELING AND SIMULATION tools are impacting thedesign and evaluation of mechanical stronglinks. The Sci-ence Based Engineering & Technology concepts beingapplied to stronglinks include deformable mechanics (tosimulate mechanical shock response); rigid-body mechan-

ics (to simulate complexmechanisms); and thermal-structural mechanics (to sim-ulate welding). Simulations ofdetailed models of the W76-1 and W80-3 stronglinkshave demonstrated theirvalue to product realizationfor the life extension pro-grams. Detailed models ofstockpile stronglinks have

been constructed through the Enhanced Surveillance Pro-gram, to enable a simulation-based approach to life-cycleperformance evaluation. (1500, 2600, 2900, 8700)


The W87 System Engineering Group flight-tested (seeimage above) the first of a new series of Joint Test Assem-bly (JTA) reentry vehicles (designated JTA4) on August 25,2005. The near-flawless performance of the advancedmodular telemetry and instrumentation system providedcritical qualification data for the new W87/Minuteman IIIweapon configuration. The JTA4 series is designed to pro-vide an enhanced fidelity measurement platform forobtaining stockpile surveillance flight test data for the

W87 and Minuteman III programs. (8200, 1700, 2500,2600, 5300, 12300)

Sandia deployed a Radiological Assistance Program team toassist White Sands Missile Range in resolving a problemwith a stuck 15 kiloCurie Cobalt-60 source at its Gamma-Irradiation Facility. The RAP team, consisting of personnelfrom Emergency Response Systems Engineering Dept.12345 and Mobile Robotics Dept. 6644, successfullyreturned a source to a safe condition with minimal radi-ation dose to personnel. Activities included tooling devel-opment, robot repair, entries into a potentially lethal radi-ation area, and dynamically modifying a Sandia robot toperform the most hazardous operations. The front coverphoto shows the robot modified by the team to solve theproblem. (12300)

In February 2005 the W76 Weapon Assessment Teamprovided an independent nuclear surety assessment ofthe W76-1 final design. The team’s assessment consideredanalysis representing the following disciplines: nuclearsafety, reliability, quality, surveillance, and security and usecontrol. The assessment is prepared for the Executive VPand Chief Engineer. The formal analysis allows the W76-1Weapon Project Team to focus further surety efforts onhigh-priority nuclear surety concerns. (12300)

The MESA project accomplished 25 percent of the overallwork scope last year on time and on budget. The overallproject is some three years ahead of schedule, more

than 70 percent complete, and projecting significantcost savings. The MESA project team’s major achieve-ments last year included: a New Mexico Quality “Road-runner” recognition award, start of the Weapons Integra-tion Facility construction, ISO Class 4 cleanroomcertification in the new MicroFab facility, start ofMicroFab tooling subproject, and support to the Sandiacorporate Earned Value Management Systemcertification by DOE.

The Nuclear Weapons SMU Corrective Action TrackingSystem (CATS) is an integrated process/tool that enablesmore effective, sustainable solutions for managing requiredcorrective actions. Sandia and NNSA’s Sandia Site Office areusers. CATS, based on nuclear weapons complex andindustry best-practices, is a key component of NW Perfor-mance Excellence and an ISO-9000 management system.The system incorporates a key process, workflow applica-tion, status/trending tool, online help, full training, anduser support group. (200, 2000, 4000, 10000, 12000)

Model Based Performance Analysis is using modeling andsimulation to gain a broader and deeper understandingof weapon electrical system performance. Circuit vari-ability analysis results estimate uncertainties and quantifymargins for key subsystem requirements. Modeling theW76-1 Firing Set is supporting the Life Extension Programby enabling understanding of design margins.(12300, 8200)

Nuclear weapons(Continued from preceding page)

THE CAPABILITIES OF THE CODE MANAGEMENT SYSTEM were significantly increasedto support use-control functions for several additional weapons in the stockpile (inaddition to the previously supported B61-3,4,10). The Code Management System willnext be employed by the Air Force Materiel Command to replace its aging, less-capa-

ble system. Four years of development culminated in the completion of an NNSA LevelII Milestone composed of software and hardware product Qualification EngineeringReleases. First Production was accomplished by the Honeywell/FM&T plant ahead ofschedule. (2100)

First flight of JTA4 package

The Advanced Concepts Group (Sandia’s forward-looking in-housethink tank) and WET Design, Inc., have demonstrated a large

hydraulic impulse device capable of stopping a moving vehicle, breach-ing structures, and disabling IEDs. The device, a pneumatically drivenwater cannon, shoots a column of water hundreds of feet. This proventechnology is similar to the impulse fountains used world-wide; the foun-tain at the Bellagio Hotel in Las Vegas, Nev., is a familiar example. (7000)

The Bi-National Sustainability Laboratory opened its doors in November,a project initiated and championed by Sandia’s Advanced ConceptsGroup. The laboratory, funded by the US and Mexican governments andby the State of New Mexico, aims to establish a string of researchcenters stretching from the Gulf Coast to the Pacific. Its ultimate goal isto serve as an engine of research excellence for sustained economicdevelopment along the US-Mexico border.

The ACG held a fest focused on leveraging the public to prevent and mit-igate terrorism at soft targets in the US, such as airports, shopping malls,and sports events. One idea developed at the fest is a sophisticatednational multimedia campaign called “The Art of Freedom” designedto build community, increase resilience, and give the public actionableinformation about homeland security. The Albuquerque Sunport hasfunded Marshall Monroe Magic, Inc., to further develop the proposal.The Sunport will serve as the pilot site. (7000)

Advanced concepts group

HYDRAULIC IMPULSE DEVICES, using technology similar to that which drivesimpulse fountains such as the famous display at the Bellagio in Las Vegas, mayhelp foil various terrorist tactics. (Photo courtesy Bellagio Hotel and Casino)

ComputingSandians, working with Cray Corpora-

tion, brought the Red Storm supercom-puter into limited availability. (For moreon Red Storm’s accomplishments, seefirst entry under “Nuclear weapons,”page 3.) Delivery of the hardwareduring the summer of 2005 enabledthe team to meet several NNSAmilestones. Our Linpack bench-mark performance was 36.19Teraflops on 10,848 processors,placing Red Storm at number sixon the Top500 (ranking of super-computers). Efforts are nowfocused on addressing the nuclearweapons capability computingworkload, improvements in sys-tem reliability, and parallel file sys-tem performance. (1400, 4300, 8900)

Sandia’s Computer ScienceResearch Institute broke ground inAugust on a new building “outside thefence” to enable university researchersand students to more easily work along-side Sandia researchers on large-scale com-putational problems. The 34,500-square-foot building at Sandia Science andTechnology Park will accommodate 135 Sandiaresearchers and 55 collaborators to work on large-scale computational problems critical to Sandia's mis-sion and US technological leadership. (1400)

The DART environment is a collection of software toolsthat reduce the time required to build, analyze, and under-stand complex finite element analyses. The DART team,with participation from Centers 1400, 1500, 4300, 4500,5700, 6200, 8700, and 8900, deployed the initial DART

dence over assertion” for software performanceexcellence. (4500)

In a collaborative effort involving severalComputing and Integrated Enabling Ser-

vices organizations, Sandia procuredand installed the new ThunderbirdComputer Cluster. This team workedsafely over an intensive six-monthperiod to complete the procure-ment, installation, integration, andtesting of this new machine inunprecedented time. Thunderbirdwent into production last Octoberto provide more than 8,000processors delivering 60 Tera-OPS(trillion operations per second) tomeet the laboratory’s growingdemand for capacity computing.(1400, 4300, 8900, 1900, 10200,10800)

Sandia’s Red RoSE cluster achievedproduction status in August 2005

and became one of the world’s mostcapable visualization and data manage-

ment computer systems. Red RoSE set arecord for highly interactive visualization

of large data sets by rendering 8 billion tri-angles/second. Red RoSE also set a record for

high-performance disk storage systems by pro-cessing 15 gigabytes/second. The Red RoSE clus-

ter was developed and deployed by Center 4300 tosupport the modeling and simulation environment for

the Red Storm supercomputer.

Sandia and Lockheed Martin researchers applied state-of-the-art optimization methods from Sandia’s DAKOTA soft-ware to design the external fuel tank for the F-35 JointStrike Fighter aircraft. The DAKOTA toolkit made possiblea “virtual prototyping” design process by reducing both thenumber of expensive computer simulations and the num-ber of expensive wind tunnel tests needed to refine the fueltank shape. Subsequent test data validated the predictedperformance of the new aero-shaped fuel tank for lowobservability (stealth), fuel efficiency, and flight safety.(1400, 1500, 10100, Lockheed-Martin)

The Interactive Design Center (IDC), Sandia/California’spremier facility for viewing high-resolution computer-gen-erated graphics, became operational in January 2005 andwas recently accredited for classified computing and dis-play. Funded by the NNSA’s Advanced Simulation andComputing Program, the IDC’s high-fidelity display sys-tems and advanced computational platforms enabledesigners, engineers, and analysts to interactively view, dis-cuss, and comprehend complex large-scale weapons mod-els and simulations in real time.

production release on the Sandia Restricted Network inSeptember 2005. The environment provides capabilitiessuch as consolidated analysis artifact management,improved meshing and model-building tools, unifiedASC platform and code access, and improved visualization.DART tools interoperate through the use of metadata,which frees analysts from manually translating databetween tools.

Last April, Center 4500 was awarded the Software Capa-bility Maturity Model (SW-CMM) Level 3 designationfrom the Software Engineering Institute. “Certifiedprocesses” is often a factor in qualifying providers in thedefense industry. Though CMM is a global standard and afocus of other Lockheed Martin companies, Center 4500’scertification is the first (known) among the DOE weaponslabs. The certification represents a first step toward “evi-

A COMPLEX MECHANICAL part meshed with the DART tool,CUBIT (see description below).


SANDIA’S RED STORM SUPERCOMPUTER ran a 15-hour shockphysics simulation of an asteroid being split apart by a nuclear blast.The simulation offers detail not seen in lower-resolution models.

Sandia/California’s Interactive Design Center

In the wake of Hurricane Katrina, Sandia’s National Infra-structure Simulation and Analysis Center supported theDepartment of Homeland Security by performing a

detailed analysis of the potential long-term impacts ofthe hurricane on the US economy (see image above).NISAC staff, working with six economists, labored for 36hours straight and reported the estimates of impactsdirectly to Secretary Chertoff. Subsequently, DHS praisedNISAC for providing estimates that were very close to thosereleased by the US Congressional Budget Office. Theyarrived at DHS a week before the CBO estimates. (6200)

The Operations Research & Computation Analysis(ORCA) provided key infrastructure and modeling analysisto NISAC’s Fast Analysis Support Team as part of Sandiasupport to the DHS after hurricanes Katrina and Rita (seeentry above). ORCA used the Railroad Network AnalysisSystem, which it designed and developed, to determine thehurricane-related impacts to the national flow of com-modities on the rail system. Rail outages were also trackedto provide DHS with a com-prehensive status of the railsystem.

The Sandia Gauntlet wassubjected to rigorous per-formance assessments at theExplosives Applications Lab-oratory, Site 9930. A newgun, necessary for these tests,was developed by Dept. 5122personnel. The penetrationvelocity for the four frag-ments exceeds the require-ment for the Army’s inter-ceptor body armor. The finalround of testing included acommercially availableKevlar material (KM2). Tensets of gauntlets have beendelivered to the US Army fortesting and evaluation, and50 sets are being finished forthe US Air Force Battle Lab. Apatent application has beenprepared and submitted. (5100)

In November 2004, a fire started in the Rocket ShearMachine at the Umatilla (Oregon) Ammunition Depotduring demilitarization processing of M55 rockets (seeimage below). Months later, two additional incidents

occurred at the facility during the same process. TheChemical Materials Agency (CMA) asked Sandia to providean independent review of the depot’s processes. Repre-sentatives from Explosives Applications Dept. 5122 visitedthe facility and developed a report identifying likely prob-lem areas and suggesting possible improvements. Plantoperations were restarted after process improvements wereimplemented, based in part onthe report. No subsequent acci-dents have occurred. (5100)

Sandia led completion ofRemotely Operated WeaponSystems (ROWS — see photobelow) at two sites this year,the Y-12 Plant and a US AirForce installation. The system’sadvantages include the abilityto respond to multiple threatsand locations from one com-

mand cen-ter, andincreasedfirepowerwith reduced costs, with accuraciesthat approach and sometimes exceedthose of humans. Sandia continues torefine the effectiveness of ROWS byproviding operators with situationalawareness and targeting tools.(6400, 6600)

With sponsorship from the NationalInstitutes of Health, we have devel-oped lab-on-a-chip technologies forrapid detection of periodontal dis-ease biomarkers using tiny amountsof saliva. In many applications, salivais preferred over other body fluids as itcan be noninvasively and inexpen-sively collected. The device beingdeveloped is portable and targeted forpoint-of-care application such as a doc-tor’s or dentist’s office. Our lab-on-a-chip technology is also applicable to

diagnosis of a wide range of oral and systemic diseases,including potential exposure to biological agents.

A team of Sandia engineers, analysts, and computer scien-tists has completed initial development of a powerful setof tools to help protect our borders. The focus of this

Grand Challenge LDRD was to develop simula-tion-based systems analyses characterizing thesecurity of the US border and the impact ofnew detection technologies. Preliminary analy-ses of seaport, airport, and land crossing check-point operations have generated significantinterest from Customs & Border Protection, theDomestic Nuclear Detection Office, and variousgovernment contractors.(6200, 6400, 6600, 8100, 8200)

The BioDAC (Biological Decision Analysis Cen-ter) simulation was developed and used suc-cessfully for DoD and Department of Home-land Security-sponsored bioterrorism exercisesand analyses through the BioNet Program. In

the exercises, civilian and military role-players usedtheir response strategy in scenarios and examined howtheir ConOps and physical systems might be effective indetecting and characterizing an attack. Participantsincluded senior DoD and DHS officials; local public healthofficials; and US Navy health, fleet, and installation com-manders. (8100, 8500, 8900, 4500)

The Rapidly Deployable Chemical Defense (RDCD)system, designed for the Department of Homeland Secu-rity, is an early-warning chemical detection system toprotect against chemical threats at National Special Secu-rity Events. A multilaboratory team (Sandia, LawrenceLivermore, Pacific Northwest, and Los Alamos) developeda system solution that includes a ground-based detectionsystem, dispersion modeling, meteorological informa-tion, and an air-based detection system. Sandia serves asthe program lead and developed the ground-based detec-tion system consisting of eight nodes, which includedetectors, communications, video surveillance, and amulti-communication mode Sensor Management Archi-tecture. (8100, 8200, 8500)

Operation America, a five-day workshop on advancedbomb-disablement technology for bomb squad personnel,was conducted in November in Albuquerque. The pro-gram, hosted by Sandia, was cosponsored by DOE and theAlbuquerque Police Department bomb squad. Sixty-fiveparticipants from 12 states, all branches of the US military,and Canadian police and armed forces units attended.Three days of technical presentations, tools, and tech-niques were followed by live-range demonstrations andparticipation in realistic scenarios held throughout theAlbuquerque area (see image above taken during a scenarioexercise at a local high school).


Homeland Security

A BioDAC simulation exercise.

Photo by Randy Montoya

Photo by Randy Montoya

Photo by Mike Janes

The Laser Dynamic Range Imager(LDRI), developed in Dept. 2624, was

the primary tool of choice for NASA toinspect the space shuttle Discovery whilein orbit, during the historic “Return toFlight” mission. The sensor was used byastronauts to identify and characterizepotentially catastrophic damage to theshuttle’s thermal protection system.Along with the LDRI sensor, we devel-oped and delivered an extensive imagingprocessing capability for Mission Control.The Sandia mission control team pro-duced enhanced visualization andvibrometry data during the mission.(2600, 1500, 2300, 2400, 4300, 5400,5600, 5700, 5900, 12300)

RF (radio frequency) microelectro-mechanical systems (MEMS) are beingdeveloped for applications that demandworld-class electrical performance andextremely high reliability. Understandingof the behavior of these designs throughobservation or measurement is difficultdue to the designs’ microscale time- andlength-scales. These technical challengeshave been successfully tackled by a cross-center team at MESA-TOP led by Dept.1742. The team used advanced simula-tion capabilities and microsystem diag-nostics to reveal and address unantici-pated dynamics, thereby achievingsignificant advances in reliability.(1500, 1400, 1700, 2600)

Sandia developed the Global PositioningSystem (GPS) Joint Program Officecrypto-processor used in militaryreceivers. The crypto-processor imple-ments critical security functions neces-sary for US battlefield superiority,including Over-The-Air-Rekey (OTAR).OTAR lets military receivers securelyupdate crypto keys in the field via satel-lite data transmissions, greatly simplifyingcrypto key management. In FY05, Dept.2622 supported a full system test of theOTAR capability using Control Segmentbroadcast to live satellites. This demon-stration was a resounding success and anessential step toward full operationalcapability of the next-generation GPS security. (2600, 1700,5600, 12300)

We participated in two launches last August as part of theMissile Defense Agency’s Critical Measurements and Coun-termeasures Program. This program involved Sandia, OrbitalSciences Corp., and MIT’s Lincoln Laboratory. The flightslaunched from Sandia’s Kauai Test Facility. The missions area vital part of the Ballistic Missile Defense System risk-reduc-tion effort, testing critical system elements and system-levelissues. The successful flight test campaign provided the mostchallenging target scenario to date to support ballistic missiledefense development. (2600, 5300, 5400)

Penetrator Technology Dept. 5431 successfully conductedfull and subscale tests with the mobile guns at the White

Sands Missile Range last fall. We met our Defense ThreatReduction Agency customer objectives, collecting onboardprojectile deceleration data in the full-scale test units. Usingthe Sandia 3-axis millipen hi-G data recorder and a SIPEfuze, we were able to collect data in two targets with twodifferent size projectiles. We demonstrated survivability ofa jointed case versus a monolithic case under conventionalvelocity impact conditions. (2100, 2600, 5400)

Development of the Support Enterprise Model (SEM), anenterprise-scale logistics simulation tool, passed criticalmilestones in 2005. SEM is being used on the JointStrike Fighter program by LM Aeronautics, JSF ProgramOffice, and international partners to help support multi-billion-dollar design decisions and trade studies. Sandiasuccessfully completed a major upgrade, received formal

SEM code verification, and earned JSF Program User Accep-tance. Software development is being led by 6642 (with1415 providing optimization expertise) under a LockheedMartin CRADA. (6600, 1400)

The fiber laser LDRD Grand Challenge has reached a majormilestone for the laser community. Roger Farrow, PaulSchrader, Dahv Kliner, and Alexandra Hoops (8300) havedemonstrated >1.2 MW peak power from a Yb-dopeddouble-clad fiber amplifier. More recently, with a 2.3 nsseed source developed by Randy Schmitt (1100), they gen-erated >1 mJ of pulse energy with an essentially diffraction-limited beam quality. This achievement enables a widerange of applications, such as secure communications,remote sensing for reconnaissance, and 3-D mapping(ladar). (8300, 1100)

Defensesystems andassessments

THE SANDIA-DEVELOPED Support Enterprise Model is beingused to help design a global sustainment system for theJoint Strike Fighter. (Photo courtesy Lockheed Martin)

ASTRONAUT STEPHEN ROBINSON, suspended outsidethe space shuttle Discovery during the return-to-flightmission last summer, carried out unprecedented in-flightrepairs to the shuttle. Data provided by Sandia instru-mentation (see inset photo above) helped focus on thearea requiring attention.


Using Sandia’s powerful supercomputers, we’vedeveloped a new capability to accurately simu-late the probe tip of an atomic force microscope.

These simulations mimic experiments that study the ori-gins of adhesion and friction in microelectromechanicalsystems, while providing an unprecedented level ofdetail. Friction in these systems is lowered through a self-assembled monolayer coating, but wear and degradationof the coatings, particularly in the presence of water, isstill a concern. Simulations will allow researchers tounderstand factors that influence coating degradationand help designers improve overall performance. (1800)

Peter Schultz developed an innovative numericalmethod to accurately compute electronic energy levelsassociated with defects in semiconductors using first-principles density functional theory. Accurate knowl-edge of these levels is essential to predict the electricalresponse of semiconductor devices in radiation environ-ments. This breakthrough overcomes a longstandingbottleneck in modeling defect properties and enables

building physics-based defect models that meet a keyneed for the multiscale modeling and simulation effortin support of developing qualification alternatives to theSandia Pulsed Reactor.

We performed cutting-edge computational researchaimed at elucidating details of wetting in multicompo-nent polymer systems. The work was featured on thecover of Langmuir (August 16, 2005). The scenario weinvestigated (relevant to a wide range of coating technol-ogy) is one wherein a component in the liquid does not,in its pure state, wet the surface. By simulating mixturesof non-wetting and wetting material, we demonstratedunique dependencies of spreading behavior on dropletcomposition as well as the various interaction energies inthe system. (1100, 1800)

High-explosive hexanitrostilbene (HNS) has been success-fully machined into miniature rods, called “ratesticks,” using a femtosecond laser. The laser ablates theHNS, but each pulse is so short that it does not ignite.

The resulting rate sticks are believed to be the first of theirkind machined from HNS, with previously unachievablesmall diameters of less than 0.5 millimeter. At thesediameters, investigators can examine fundamental det-onation phenomena at length scales previously unat-tainable. Sandia continues to investigate fabrication ofadditional miniature test geometries to further enhancefundamental understanding of explosive behavior. (2400,2500, 8300, 6100, 1700, 6600)

Interest in the indirect bandgap Ge0 nanocrystals (seeimage below) has increased since the recognition thatthey can behave as a direct bandgap material. This newunderstanding opens the possibility of using Genanocrystals as light-emitting or power-generating ele-ments. For the first time, we have developed convenient,simple, single-source solution synthesis of Ge0 nanodots,rods, or wires, the morphology of which is dictated by themolecular precursor design. Recent results with speciallyprepared Ge0 nanocrystals demonstrated the utility ofthese species as bioimaging agents for mast cells.


Materials,chemistry,and physics

Under Sandia’s Truman Fellowship program, researchers in Center 1700 set a MEMS switching speed recordby changing states in less than 500 ns with a total displacement of 1.8 µm and using just 35 V. This is

roughly 10 times faster than all other MEMS switches with comparable displacements and voltages. Strainenergy stored in the switching structure is recycled to drive high-speed switching operation and to reduceswitching energy. Potentialapplications include RF, free-space optical, and integratedoptical (waveguide-based) MEMSswitches. (1700)

Sandia’s Low TemperatureCofired Ceramic research teamhas created an important newclass of mesoscale (millimetersize range) components. A sacri-ficial material technique elimi-nates processing steps and cre-ates the world’s first cofiredimpeller and suspended proof-mass (Fig. 1). Other cofired struc-tures include “smart” channelsfor gas (e.g., toxin) analysis, pres-sure transducers, heaters, temper-ature/flow sensors, switch struc-tures, and critical elements ofmicro “total analysis systems.” This new integrated functionality in a small volume opens the door to innova-tive designs and enhanced capabilities for weapon systems, homeland security, and commercial applications(see next entry, below). (2400, 8300, 6100, 1700, 6600)

Integrating microfluidic devices into complex microsystems — key to analytical chemistry and life sciences suc-cess — has been a barrier to microsystems development. As featured on the September cover of the InternationalJournal of Applied Ceramic Technology, a Sandia breakthrough has been made that uses low temperature cofiredCeramic manifolds with internal passageways to marry miniature devices to standard connectors. Thisenables easy integration and testing of microsystems using silicon microfluidic valves, mixers, pumps, andsensors. Potential applications for such integrated microsystems include braille readers, biological cellcharacterization, and weapon systems. (2400, 8300, 6100, 1700, 6600)

Microsystems

CLOSE-UP of a simulation inwhich an uncoated silicon diox-

ide probe tip (radius of curva-ture 10 nm) is brought into

contact with a self-assembledmonolayer-coated surface.

Ge0 (a) nanodots and (b) nanowires formed from Ge(II) precur-sors: (a) amide, and (b) aryloxide.

MESOSCALE COMPONENTS — a) The first-ever functional-as-released freely spin-ning impeller in low-temperature cofired ceramic has survived one million revolu-tions; b) Proof-mass is suspended by low temperature cofired ceramic tethers.

The Test Capabilities Revitalization project teamcompleted phase 1 ($47.2 million) of a congres-

sional line item project to restore Sandia's test capa-bilities. The project provides new qualification,weapon development, and model validation capabili-ties. Phase 1 enhanced the Aerial Cable Facilitymechanical testing capabilities and constructed aone-of-a-kind Thermal Test Complex to performabnormal thermal environment testing and firephysics R&D. The cable facility has already supportedmultiple B61 and B83 surveillance and B61 ALT 357certification tests. The Thermal Test Complex will beused this year to support W76 and W80 LEP qualifi-cation efforts. (1500, 10800)

The Advanced Simulation and Computing Verifica-tion and Validation milepost “W76-1 HostileMechanical Response to Blast” was completed inAugust 2005. The body of work represented the cul-mination of a three-year effort to enable a newapproach to model validation based in an uncer-tainty framework with quantitative assessments ofmodel validity. The ASC advisory panel praised theteam’s “dedication and commitment to producingquality work” and further acknowledged its historiccontribution to the development of tools and meth-ods for modern predictive science.

Sandia staff have contributed to the development ofthe next-generation destroyer for the US Navy,with experiments, analysis, and model development.In partnership with Navy labs and contractors, wehave conducted a series of experiments to helpunderstand the behavior of energetic materials invarious accident environments. The data have beenused to develop new models of propellant and high-explosive behavior. The models are now being usedwith Sandia-developed codes to design key aspects ofthe weapon delivery system.

Structural ceramics are used for armor, but they alsoappear in myriad commercial applications wherevera lightweight, strong, and heat-resistant material isneeded. Recognizing that fabricated brittle materials

Engineeringsciences

Apartnership between Sandia and Compa Industries has developed a medicalsensor called µPosts (microposts) that could give physicians a greater under-

standing of a patient’s health in a shorter amount of time. µPosts (see above) aremicron-scaled posts that painlessly penetrate the skin of a patient and detect manysignificant biological markers. With the µPost medical sensor, hundreds of measure-ments may be taken simultaneously. To date glucose and heart attack markers havebeen measured in skin. (1700, 2500)

A computer cognitive model of an automobile driver uses information from thevehicle such as wheel speed and steering wheel rotation to infer driving contexts(e.g. entering roadway). Based on these driving contexts, the vehicle recognizeswhen the driver is in a difficult situation and can adapt appropriately. For instance,an incoming cell phone call may be momentarily blocked. This technology hasbeen integrated into a Mercedes G-Wagon for operational testing by the USMarine Corps. (6600).

The continued growth in energy demand is driving increasing interest in renewableenergy. Solar energy is a promising candidate, but much progress is necessary toovercome efficiency and economic factors. Nanostructures may present a uniquesolution to the problem, by offering new electronic structure, low losses, andentirely new functionality. Francois Leonard (8764) and Derek Stewart (now at Cor-nell) calculated that a single carbon nanotube, just a nanometer in diameter, canserve as a broadband optical energy conversion material. This fundamental under-standing may pave the way for future all-carbon solar cells.

Biotechnology/Nanotechnology

The Environmental Restoration Project completed the final phases of its last twomajor remediation projects. A cover was installed on the Chemical Waste Land-

fill, completing more than eight years of remedial activity that included extractionof a solvent vapor plume and exhumation of a wide variety of materials disposedby Sandia between 1962 and 1985. Also, the last of more than two millionartifacts dug up from the Classified Waste Landfill were demilitarized and sanitized.This activity concluded six years of effort since excavation of the landfill beganin 1999. (6100)

Teamwork was evident during the highly successful chemical inventory reduction cam-paign of 2005 at Sandia/California. The effort resulted in a reduction of 15 percent ofthe total chemical container count (approximately 5,000 items) including some 700 ofthe most hazardous items. This campaign began as an Emergency Management/ES&Heffort to reduce the inventory to minimize risk to on-site personnel and the surround-ing community. We achieved synergy by blending a corporate self-assessment “House-keeping” finding corrective action and an Environmental Management System-estab-lished 10 percent inventory reduction goal.

Employee accidents and injuries dropped for the fourth consecutive year. TheTotal Recordable Case Rate (injuries requiring more than first-aid treatment)dropped to 2.6 during the 2005 calendar year from 3.0 in the same period lastyear — and down 37 percent from 2002. Last year, Sandia achieved the first weekin five consecutive years without a recordable injury. There were no recordableemployee injuries for the week of Sept. 12-18. The last time this occurred was inSeptember 2000.

Among the prestigious awards bestowed last year on Sandia’s Environmental Man-agement Program were several top national and local honors. Sandia earned threeNNSA Best-in-Class Awards for such work as the Joint Computational EngineeringLaboratory (Bldg. 899) and Sandia’s first green building (Bldg. 805). Sandia/DOEearned The City of Albuquerque’s Top Wastewater Prize in the “Industrial Pretreat-ment Excellence Award for Wastewater Program.” Sandia also received the WhiteHouse “Closing the Circle Award” for green purchasing and the EPA’s “Waste WiseAnnual Award” for solid waste reduction.

To reduce accidents and injuries, a behavior-based safety process was implemented inDivision 10000. It involved workers anonymously observing colleagues to reinforceprecautions in safe use and provide information and reminders to help implementprecautions and identify obstacles. Implementing the process has been shown tolower injuries by at least 25 percent within the first year and up to 80 percent in threeyears. Several precautions were identified to prevent 62 percent of Division 10000’sinjuries: body alignment, getting help, footings, line of fire, eyes on path, andhands/eye personal protective equipment.

ES&H

share many of the modeling challenges intrinsic to naturallyoccurring rock, Geomechanics Dept. 6117 teamed withdepartments 1431, 1674, and 1647 to provide the ArmyResearch Laboratory with enhanced models, resulting in

unparalleled mesh-independent and accurate predictionsof cracking patterns and penetration resistance. This willhelp the Army more efficiently determine armor characteris-tics to protect our troops. (6100, 1400, 1600)

THERMAL TEST COMPLEX


THE SIDE VIEW of a single hollow µPost. The µPost is usedfor the capture and measurement of proteins using afluorescent dye (green hue).


Energy, security, and defense technologiesCombustion researchers Jacque-

line Chen and Evatt Hawkeswere awarded 2.5 million hours —more than five percent — on DOE’sOffice of Science supercomputer atLawrence Berkeley National Labora-tory to carry out a combustion simu-lation of unprecedented complexity(see image at right). The computingtime, awarded on the basis of anational competition, enabled theresearchers to run the largest-ever3-D direct combustion simulationof a turbulent CO/hydrogen flame inwhich the fuel and oxidizer are notpremixed. The data will be used tounderstand turbulence-chemistryinteractions required to design morefuel-efficient, cleaner-burningengines.

The Directed Energy Laser Applica-tions Department (5100) has builtthe world’s highest peak-powerlaser in the mid-infrared region(1.5-5 µm). The Optical ParametricChirped Pulse Amplifier (OPCPA)uses a parametric mixing process togenerate high peak-power pulses atwavelengths of 1.55 and 3.4microns. Both wavelengths areimportant for remote sensing andnonproliferation applications. Thissource has allowed the group tomake unique discoveries in the fieldof nonlinear optics, which are beingunveiled to the scientific commu-nity for the first time through severalupcoming publications.

Many Sandians worked together to plan and execute an event celebrating President Bush’ssigning of the Energy Policy Act of 2005 Aug. 8, 2005 (see event photo on page 2). Theevent at Sandia included a 20-minute tour of the National Solar Thermal Test Facility, con-ducted by Tom Hunter, prior to the bill signing. President Bush was accompanied by DOESecretary Samuel Bodman and N.M. senators Pete Domenici and Jeff Bingaman. The eventhighlighted the role Sandia can play as a contributor to the nation’s energy security.

Predictive combustion models require detailed chemical mechanisms. Recently an interna-tional team, led by Combustion Research Facility researchers Craig Taatjes, Nils Hansen, and

Andrew McIlroy, discovered that a class of moleculesabsent from present oxidation models, the enols, isubiquitous in hydrocarbon combustion. Enols are theless-stable isomers of well-known combustion inter-mediates such as aldehydes and ketones. Erlenmeyerpredicted their existence in 1880, but none weredirectly observed until 1973. Hydrocarbon oxidationmechanisms must be modified to account for thechemistry of these unexpected compounds. The workwas featured as the cover story in Science magazinelast June.

Sandia has developed new modeling and simula-tion capabilities for application to advanced armorsystems being developed at the Army Research Labo-ratory (ARL). Magnetohydrodynamics capabilitiesdeveloped for Z-pinch modeling, improved equationsof state and electrical conductivity models developedfrom quantum molecular dynamics simulations, andnew ceramics models employing statistical variabilityto eliminate numerical dependencies, have been inte-

grated in the ALEGRA-MHD code. Analysts at ARL are now using ALEGRA-MHD simulationsto help guide experimental work on improving the resistance of new armor concepts to vari-ous penetration threats. (1400, 1600, 6100)

We installed and tested a robotic projectile download workcell to disassemble 155mmADAM Improved Conventional Munition projectiles in the state-of-the-art MunitionsCryofracture Demilitarization Facility at the McAlester Army Ammunition Plant inMcAlester, Oklahoma. The workcell removes people from the potentially fatal hazardsthat occur annually in a worldwide industry. The Defense Ammunition Center usedSandia technologies developed under the DOE/DoD Advanced Munitions MOU Program.

Sandia has developed a new familyof flexible flight computers calledIMPACCT that addresses a nationalneed for economical computer solu-tions for high-consequence aero-space applications. IMPACCTembodies a flexible design conceptcombining Sandia custom subassem-blies with commercial computermodules. Aerospace Systems Devel-opment Center 5400-sponsoredgraduate research at Kansas StateUniversity has produced student-inspired versions of IMPACCT thatwill be demonstrated on upcomingMissile Defense programs in FY06.Two KSU students last year earnedIMPACCT-related MS degrees andnow are helping sustain develop-ment and application efforts asmembers of Sandia’s technicalstaff. (5400)

Sandia researchers invented andtested new desalination andarsenic-removal technologies whilealso helping New Mexico communi-ties develop new sources of arsenic-free drinking water. Desalinationefforts at Sandia involved researchersfrom several organizations whoexplored biomimetic separation ofsalts from water by cellular processes,freeze distillation, and advancedmembrane synthesis. Research alsoexplored the possibility of recoveringdrinking water from petroleumextraction wastes. In conjunctionwith the research, pilot-testing, tech-nology commercialization, and out-

reach efforts are identifying paths for lowering arsenic levels in drinking water nationwide.(6100, 6200, 8300, 8700, 1000)

The nuclear power industry is turning to dry-cask spent-fuel storage systems to augment on-sitespent fuel pools. Casks are typically tall, vertical, free-standing cylinders that might slide or tip

during a strong earthquake. In work for the NRC, Sandia developed a comprehensive finite ele-ment methodology for evaluating cask response to seismic ground motion, including anintegrated model of the soil, concrete pad, and the cask. The NRC will use the analysis resultsin licensing reviews to ensure system safety. (6800, 5400)

Sandia has developed an extensive array of analytical tools and experimental facilities toassess physical protection system performance. Center 6400, working closely with a nuclearutility, demonstrated the applicability of this security technology base to the development ofoptions for improved protection of nuclear power plants against terrorist attacks. Theutility participants are enthusiastic about using Sandia technology. The tools and techniquesenable them to perform cost/benefit analyses for security upgrade options, support trainingof security personnel, provide a cheap and safe alternative to supplement force-on-forceexercises, and evaluate the effectiveness of tactical response options.

Center 6800 leads an international effort involving DOE, France’s atomic energy organiza-tion, and General Atomics to develop the sulfur-iodine thermochemical cycle for emis-sion-free hydrogen production using high-temperature heat and water. In FY05, Sandia per-formed experiments to demonstrate high-temperature sulfuric acid decomposition, one ofthe three primary reactions in the sulfur-iodine cycle. The experiments demonstrated theprocess chemistry and materials technology that will provide the basis for an integratedinternational experiment at Sandia in FY2007. (6800)

From the beginning, Sandia developers of the Army’s Explosive Destruction System (EDS) forchemical warfare munitions suspected that it could also destroy biological agents such asanthrax. Sure enough, under LDRD funding, researchers confirmed EDS’s effectivenessagainst bio agents. Three treatment approaches were investigated: steam autoclave, gasfumigation, and liquid decontamination. Each resulted in complete neutralization ofanthrax simulant bacterial spores. First delivered to the Army in 1998, EDS is a transportablesystem that has neutralized recovered chemical munitions in more than 225 operations insix states and England. (8200, 8700, 5100)

A Sandia team, teaming with researchers from UNM and Lumileds, a leading light-emittingdiode (LED) manufacturer, have demonstrated significant (1.6x) improvements in thelight output from visible LEDs using photonic lattices (see images at left). Advanced devicemodeling and design, nanolithography, and novel process development enabled thedemonstration of these photonic crystal LEDs using InGaN materials. (1100, 1700)

SCALAR DISSIPATION rate, a measureof the local mixing intensity, in a turbu-lent CO/H2/air jet flame.

CYLINDRICAL cask and storage field.

LIGHT OUTPUT from a blue InGaN LED with (a) and without (b) a photonic lattice on the sur-face. The radiation patterns match the symmetry of the lattices.

(a) (b)

ENOLS make cover of Science.

The 23rd Defense Support Programsatellite (DSP-23) was shipped from

Northrop Grumman Space Technologies inLos Angeles to Cape Canaveral in Floridalast May. DSP-23 is the last DSP satellite andthe last of a long string of radiation detec-tion (RADEC) and Advanced RADEC pay-loads that are and have been key to thenation’s capability to detect both endoat-mospheric and exoatmospheric nuclear det-onation events. The DSP RADEC programhas been a long-standing model example ofcollaboration between LANL and Sandia inservice to the nation.

Sandia’s most complex satellite system todate completed its Critical Design Reviewmilestone, clearing the way for fabricationwith system-level deliveries slated for earlythis year. The system is a technology-drivensystem-level development program that pro-vides a Sandia-unique solution to criticalnational needs. Sandia’s system engineeringcombined with key technologies enable thisstate-of-the-art system capability. Key tech-nologies include large-format focal planearrays, reprogrammable integrated circuits inradiation environments, precision pointingand control, high-throughput, low-latency,ground-based data processing, and support-ing mission analysis. (5300, 5500, 5700)

Photonics Microsystems Technologies Dept. 1713 hasdelivered diffractive optical elements (DOEs), as next-generationflight compo-nents, advanc-ing spectralremote sensingcapabilities inthe Nonprolif-eration andAssessmentSMU. These sur-face-relief phaseDOEs directmore than 80percent of thetransmittedlight into the dispersed order while allowing a small,broadband, zero-order beam for alignment. This representsa 4x increase in transmitted light over previousapproaches. Completion of the DOEs challenged Sandia’slithographic fabrication and numerical modelingresources. We continue fundamental diffractive opticsresearch that is relevant and responsive to all Sandiacustomers. (1700, 5700)

We have developed a technique to better solve registra-tion issues associated with challenging image-pairs. Fewof the current image registration approaches include ameasure of the statistical confidence associated with a solu-tion. Such a measure is essential for many autonomousapplications involving dubious registration solutions. Thenew approach employs the application of a well-estab-lished statistical procedure to select a “best” solutionamong a number of edge-detected candidates. Theapproach has been validated through an extensive simula-tion study, and has performed successfully in many appli-cations to challenging real-world scenarios. (5500)

Sandia’s biosecurity team made great strides in promot-ing biosecurity, which aims to stop bioterrorism before itstarts by securing dangerous bio agents. Through interna-tional conferences and workshops, the team providedinternational scientific, policy, and law enforcement com-munities a thorough technical introduction to biosecurity.The conferences have led to laboratory biosecurity becom-ing a legislative and technical priority issue in many Asiancountries, which have sought Sandia assistance in

developing biosecurity systems. The team conducted work-shops in Singapore, Malaysia, and Thailand, and visited labsin Indonesia, India, Japan, the Philippines, and Pakistan.(6900)

We have developed a training course that provides anintroduction to cryptography through four half-day ses-sions. The Crypto Course topics include an overview, his-tory, and details of both symmetric key and public keycryptography, covering various aspects of these technolo-gies such as encryption and decryption algorithms, digitalsignatures, authentication, hash functions, side channelattacks, and key exchange methodology. Those wishingonly a high-level overview (managers and project leaders)can sign up for just the first half-day session. (5600)

Researchers in Signal Processing and Research Dept. 5937have designed a next-generation real-time syntheticaperture radar (SAR) image formation and exploitationprocessor. Built around alow-cost, ruggedized, fullyscalable architecture, thisrevolutionary system isslated to fly this year on aGeneral Atomics aircraftin a first-ever demonstra-tion of strip-mappingcoherent change detec-tion (CCD). That is, theprocessor is designed tokeep up with thedemands of forminghigh-resolution imagesand performing CCD pro-cessing in a continuousfashion at aircraft veloci-ties. (5900)

Sandia has delivered thesecond of the next-gener-ation Global Burst Detector payload for integration withthe second Block IIF Global Positioning System spacecraftat the Boeing Satellite Systems facility in El Segundo, Calif.The detector system encompasses a suite of sensors thatperform the nuclear event monitoring mission of the USNuclear Detonation Detection System. The sensors aredesigned and produced by Sandia and Los Alamos NationalLaboratory, with Sandia responsible for overall system engi-

neering and integration.

Sandia led a multi-institutionalR&D proposal team in processcontrol system security funded bythe Institute for InformationInfrastructure Protection (I3P).The unique aspect of this projectis that the team includes 11 insti-tutions working on a single pro-ject focused on securing theinformation infrastructure of thegas and oil sector. Team partici-pants included researchers andengineers from Dartmouth Col-lege, the universities of Virginia,and Illinois, Pacific NorthwestNational Laboratory, SRI, Univer-sity of Tulsa, MITRE, I3P, MIT,

NYU, and Sandia. (5600)

The next-generation Inte-grated Correlation and Dis-play System (ICADS), a $190million project, continues todefy the fate of similar DoDprojects plagued by costoverruns and schedule slips.ICADS, part of the USNuclear Detonation Detec-tion System, processes datafrom sensors aboard GlobalPositioning System andDefense Support Programsatellites. ICADS consists ofa million lines of code andhardware located at sevenfacilities, and was handedover for system verificationtesting right on schedule.This milestone is the initialstep of a year-long AF opera-tional test process. (5700,5500, 2600)

Sandia’s Information DesignAssurance Red Team(IDART), part of the Informa-tion Operations Center(5600), assisted inMicrosoft’s process to

improve system integrity, privacy, and data security for itsNext Generation Secure Computing Base. An existing redteaming course was modified to include IDART’s softwarered teaming methodology and then delivered to Microsoft.The project extended Sandia’s capability in the areas of soft-ware assurance, trusted software, and information opera-tions. This was Sandia’s first major technology partnershipagreement with the global software leader. (5600)

REDTEAM2005 was a resounding success as the firstcross-governmental red team conference with attendanceof 250 representatives from 60 government and militaryorganizations. Hosted by the Information Operations RedTeam & Assessments program, part of the InformationOperations Center (5600), it was supported as a cross-San-dia effort. Themes for the event were Information Opera-tions — supporting needs in DoD; and Homeland Security— supporting DHS and NORTHCOM. REDTEAM2006 willbe held in May. (5600, 4100, 5900, 12300, 15200)

This year Sandia began anew Quantum InformationProcessing Initiative,directed at making Sandia aCenter for Engineering ofquantum systems. Small-scale quantum systemshave demonstrated utilityin computing (see image atleft), communications, andsensing applications. Scal-ing these to a useful sizecould have significantimpact on a number ofnational security chal-lenges, including cryptog-raphy, secure communica-tions, and sensing. Severalprograms were begun thisyear, including hardware-

and algorithm-oriented LDRDs, an ARDA-funded project todevelop micro-fabricated ion traps, and two DARPA pro-jects. (1100, 1400, 1700, 4300, 5600, 5900)

The “International Conference to Engage Iraq’s Scienceand Technology Community in Developing its Country”took place in Amman, Jordan, last September. Of the 175participants, more than 80 Iraqi vice-ministers, scientists,engineers, and university administrators participated. Thirtygrant proposals focusing on environment, water, agricul-ture, health, materials science, and business were presentedto the international funding community. Representativesfrom several sponsoring organizations spoke with the Iraqisabout funding requirements. Proposals when matched withfunding partners will re-engage Iraqi scientists with theirglobal colleagues while reconstructing Iraq.

Sandia researchers, working with Israeli and Jordanianofficials, extensively tested a personnel explosives detec-tion portal at the Allenby/King Hussein border crossing.Test data for the commercially available system based onSandia technology have been shared between the twocountries and the system has been certified for operationaluse. Use of the portal has cut the time of entry into theWest Bank from three hours to one hour and has signifi-cantly reduced the number of pat-down searches thatmade border crossings difficult and time-consuming.

Nonproliferation

AXIAL VIEW of pseudopotentials calculated for a three-elec-trode-level Paul trap designed to confine a linear array of ionsfor quantum computing experiments. Ions are confined atthe center by micro-fabricated electrodes on either side.

ATTENDEES AT A SANDIA-SPONSORED conference on biosecurity issues in Malaysia. Sandiaconducted similar workshops in Thailand and Singapore.


A Defense Support Program (DSP)satellite is shown on orbit in this AirForce illustration.

Atomic Force Microscopy profile of a surface-relief phase diffractive optical element (DOE).

Maintaining the desired internal atmosphere for her-metic devices is essential for long-term component

reliability. There’s a catch, though: verifying hermeticitybecomes much more difficult, but no less important, aspackage size decreases. New MEMS packages (about thesize of a grain of salt) have an internal volume of onlynanoliters. Methods and hardware were developed thatenabled successful sampling and quantitative analyses ofthe internal gas atmosphere of nanoliter packages. Thetechnique is a radical jump from previous methods forcommon electronic packages having many orders of mag-nitude more volume (hundreds of microliters). (1800)

The Ion Photon Emission Microscope, or IPEM, earneda 2005 R&D 100 Award. The IPEM technique is based ondetermining by projection optical microscopy the positionan individual ion enters the surface of the sample. Thisposition is correlated with the ion-induced signal gener-ated in the device under test, such as a malfunction in anintegrated circuit. The IPEM will be useful for terrestrial

radiation effects mapping by commercial integrated circuitmanufacturers and for radiation-hard IC testing atcyclotron labs. (1100)

Two nuclear micropower approaches have shown thepotential to safely deliver milliwatts of electricity fordecades. A robust 4.4-cm3 thermoelectric device (a cubiccentimeter is about the size of a sugar cube) demonstrated0.34 milliwatts electric in tests, with promise of approxi-mately one milliwatt. A thermophotovoltaic device, mean-while, demonstrated 1.3 mW electric from a tiny, 900Kradioactive pellet, with an ultimate potential of >10 milli-watts/cm3. These devices point to 10-to-1,000-timesimprovements over commercial battery energy densitiesand could be invaluable in weapons and unattendedsensor applications. (1700, 1800, 2500, ORNL)

The Terahertz Detector Team achieved dramatic perfor-mance improvements in a unique detector of terahertz-frequency electromagnetic radiation. The detector, withimportant potential applications in chem/bio and con-cealed weapons/materials identification, uses charge-den-sity oscillations, called plasmons, rather than electron cur-rent in a specialized transistor. Plasmons greatly increasetransistor speed and yield the advantage of all-electronicfrequency tunability. This device has the unique propertyof generating spectroscopic information with no movingparts. (1100, 1700)

The world’s smallest fine-resolution synthetic apertureradar flew for the first time last May, making high-resolu-tion real-time images at kilometer ranges. It was a dramaticdebut for MiniSAR, a 25-pound instrument package thatcan be used for all-weather, 24/7 intelligence, surveillance,and reconnaissance (ISR) on near-model-airplane-sizedUAVs. Potential customers in the military and industryhave expressed interest in not only applying the currenttechnology to ISR applications, but also to commercializeMiniSAR. (5300)

Friendly fire is a tragic and difficult-to-completely-avoidreality in combat. Now, Sandia researchers are doing some-thing to minimize it. Labs researchers demonstrated theAthena Radar-Responsive Tag during Exercise “UrgentQuest” in the UK. During the exercise last summer, Athena

tags were placed on military vehicles. The tags can be“seen” by aircraft radar, which recognize them as belong-ing to friendly forces. During the demonstration, aircrafton bombing runs used their radar systems to ensure therewere no friendly troops in their sights. If a tagged vehiclewas present, the pilot was alerted, avoiding a potentialfriendly fire incident.

With their virtually 1-dimensional geometry, semicon-ducting nanowires represent a new class of materialswith unique electronic and optical properties that couldhave applications ranging from visual displays to sensorsfor chemical and biological agents. The focus of intenseresearch around the world, the systematic characterizationand assembly of nanowires into electrical devices and therealization of electro-optical circuits remains a formidablechallenge. Sandia researchers have developed a simple plat-form that streamlines the integration and testing of a largenumber of nanowires, providing both electrical and opticalcharacteristics with statistically meaningful results.(8700, 1100, 8200)


Electronics

Supernova remnants are radiative shocks that exhibit a large amount of structure and may play arole in star formation. In experiments with the University of Texas using the Z-Beamlet laser, we

modeled the growth of such structures by tracking the evolution of perturbations induced onthe surface of nearly spherical blast waves. A unique feature of our experiments is the ability toinduce perturbations of different wavelengths using wire arrays. The measured perturbation decayrates are in substantial agreement with a theory proposed by Vishniac in the 1980s. (1600)

Our 3D electromagnetics modeling code, Emphasis/Nevada, was used to model the detailed, time-dependent performance of the complex water convolute component in the ZR accelerator. Empha-sis/Nevada simulates full electromagnetics behavior using a cutting-edge, finite-element formulation.Using standard analysis techniques, we also constructed an electrical circuit model of the convolute forthe ZR system model. The 3D modeling identified a problem with the water convolute that we cor-rected in the final design, thereby improving the performance of ZR by more than a million amperes.

Following its successful deployment of flash X-ray radiography on the Armando sub-crit experi-ment at the Nevada Test Site, the Advanced Radiographic Technologies Program has met a cor-porate level 2 milestone with the completed construction of the Radiographic IntegratedTest Stand (RITS). The RITS-6 accelerator is designed to deliver 11 MV, 125 kA, 60-ns pulses forflash X-ray radiography source development. Future experiments to be conducted in collabora-tion with the UK’s Atomic Weapons Establishment will attempt to obtain world-record X-rayintensities from a pulse-power-driven architecture.

Wire array z-pinches driven at up to 20 MA on the Z accelerator are the world’s most powerful andenergetic laboratory source of soft X-rays. Recent progress in meeting the radiation symmetry require-ments for inertial confinement fusion (ICF) has now been complemented by experiments that shapedthe soft X-ray radiation-drive time history. Nested wire arrays were shown to meet the pulse shaperequirements for high-gain inertial fusion at yields of 290-900 MJ, compatible with future applicationsof low-cost z-pinch technology to stockpile stewardship and fusion energy applications. (1600)

Pulsed Power

ELECTRIC FIELDS from a3-D Emphasis/Nevada elec-tromagnetics computa-tional simulation of the ZRmachine design. The vec-tors’ colors represent theelectric field magnitudes,where blue are lowest andred are highest magni-tudes, and the vectors’directions represent theelectric field directions.

IMAGES SHOWING TIME EVOLUTION of perturbations on blast wave. Blast wavewas created by illuminating a solid target wire, immersed in gas, with the laser.

SALT CUBES AND MEMS — 30-nanoliter MEMS package sur-rounded by table salt crystals.

FOILING FRIENDLY FIRE — Lars Wells (5354, right) and DaveErlandson (General Atomics) installing Athena tag on M3Bradley during Exercise Urgent Quest in the UK.

The 13-year old Sandia-Goodyear CRADA partnership reached a major milestone in win-ning an R&D 100 Award for the innovative use of computational modeling and simula-

tion in developing Goodyear’s new Assurance TripleTred™ line of tires. Finite elementanalysis was used to simulate traction, wear, durability, and other characteristics, andallowed Goodyear to produce a commercial product fromconcept to market in less than a year. This is a major stepalong the way in Goodyear’s use of computational simula-tion throughout its product development processes. It is aclear indication that similar gains can be made at Sandia.Sandia and Goodyear have five active projects under theumbrella CRADA, with four new projects under develop-ment. (1500, 1400, 6600, 10100)

Under a cooperative research and development agreementwith Boeing, Sandia’s EMU computer code is helping toanalyze the structural design of Boeing’s new 787 com-mercial jet. The code models patterns of damage andcracking in complex materials. Boeing has identified EMUas offering unique advantages for understanding the for-mation and effects of impact damage in composite materi-als such as those being used in the 787 wings and fuselage.EMU is based on the peridynamic mathematical theory,which originated at Sandia. Boeing and Sandia researchersare jointly developing the composite model. (1400, Boeing)

Through a Shared Vision partnership Sandia and LockheedMartin Systems Integration are pursuing a new-generationdisplay technology for military and commercial applica-tions. The technology is based on a revolutionary conceptdeveloped by UniPixel Displays, Inc. We have developedand delivered patterned aerogel thin films, a Sandia-patented technology, to serve as the ultralow refractiveindex cladding layer. Lockheed Martin believes the technology could lead to reestablishinga US manufacturing capability for thin, lightweight, low-power, low-cost displays to meetmilitary performance requirements and rugged environmental conditions. (2400, 1800)

General Motors and Sandia announced a partnership to develop and test tanks capa-ble of storing hydrogen in the form of the complex metal hydride sodium alanate. Thegoal is to develop a pre-prototype solid-state hydrogen storage tank that will store morehydrogen onboard a fuel cell vehicle than current conventional hydrogen storage meth-ods. Researchers hope to create a tank design adaptable to future improvements in metal

hydride materials. Sandia is at the midpoint of the four-year, $10 million program.(8700, 1800)

The Sandia Science & Technology Park won the US Department of Commerce Eco-nomic Development Administration’s “Excellence in Tech-nology-Led Economic Development” award for 2005. Theaward recognizes the tech park’s commitment to sound,research-based, market-driven development in helpinggrow the local economy. Battelle, Sandia MESA TOP II, andthe Sandia Synergy Center joined the Park this year.Groundbreakings were held for Poly-Flow Engineering, San-dia’s Computer Science Research Institute, and a majorexpansion for TSP. To date, 20 companies employing morethan 1,100 people are located in the Park, and investmentexceeds $178 million. (10100)

Sandia and six other New Mexico research institutionssigned the Inter-Institutional Agreement, a contract thatallows bundling of patents to promote economicdevelopment. This groundbreaking agreement providesrapid response and flexibility so that when commercial-ization opportunities arise, these institutions can quicklycapitalize on each opportunity rather than spendingtime negotiating contracts. The agreement was negoti-ated by a multi-organization team, including Sandialicensing executive Paul Smith. Signing the agreementwere Sandia, Los Alamos National Laboratory, Scienceand Technology Corporation at the University of NewMexico, New Mexico State University, New Mexico Tech,The MIND Institute, and the National Center forGenome Resources. (10100)

Sandia’s University Alliance initiative is a special licensing program that allows USeducational institutions to leverage Sandia’s MEMS capabilities. As part of the agree-ment, the school receives MEMS teaching materials, SUMMiT™ design and visualiza-tion software, training, and MEMS parts for test and evaluation. During FY05, theprogram gained 10 licenses, and has four licenses pending. University Alliance is ajoint effort to facilitate MEMS education cosponsored by the Microsystems Science& Technology and Corporate Business Development and Partnerships centers. Theprogram was honored as an industry “Best Practice” at the national 2005 MEMSEducational Workshop. (1700, 10100)

Restart of the Sandia Pulsed Reactor was approvedby DOE last September and the Safeguards &

Security Center played a significant role in theapproval. Pro Force readiness was validated, thePerimeter Intrusion Detection and Assessment Systemwas successfully tested, and the Site Safeguards andSecurity Plan was approved. Upgrades supporting theDesign Basis Threat were completed, and a complexforce-on-force exercise was conducted with no injuriesor other ES&H or security incidents.

The Security System Replacement Project is a multi-year, multimillion-dollar initiative launched two yearsago to replace Sandia’s existing alarm and access con-trol systems. The on-going project is modernizingsecurity while increasing capacity, improving alarmstation interface, and reducing maintenance andrepair costs. During the past year, Technical SecuritySystems Dept. 4214 completed the system-selectionprocess, received the first shipment of system compo-nents, completed design for the retrofit of the first setof vaults, and successfully tested the network to deter-mine optimum system configuration for potentialapplications across the DOE complex. (4200)

Every day, hackers attempt to breach Sandia’s computersystems, making rapid patching of desktops essential tocyber security. Using automated methods, Sandia’sComputing Support Services (CSS) deployed 37 setsof security updates, totaling more than 537,000 indi-vidual computer patches, on the Sandia Restricted Net-work. The time to get patches ready for installationdeclined from seven days to two. The time required to

reach at least 50 percent of Labs computers was reducedfrom two weeks to one, and will decline further withnew methods CSS has developed. (4300, 4500)

The Assurance Program’s Resolution of Findings processsuccessfully closed 65 external findings during FY 2005through a rigorous validation process conducted byNNSA’s Sandia Site Office. The team effort, whichincluded Security managers and staff from all Sandiaprograms and sites, ensured that the findings wereaddressed through formal corrective action plans.The effort resulted in an internal verification assessmentprocess, further ensuring that actions to address theproblem were completed, adequately documented,effective, and sustainable. Through this quality process,repeat problems have been virtually eliminated.

Implementation of new Security Incident Manage-ment Program procedures and changes to a corporateprocess requirement — Security Concerns ReportingProcess — led to substantial improvements in theawareness and attitude of both managers and staffregarding security incidents. The 60 percent reductionin serious incidents during FY05 indicates awarenessand attitude play a significant role in overall culturechange, a long-term initiative in the Safeguards andSecurity Program.

Using pharmaceutical molecular descriptors — signa-ture atom neighborhoods and topological indices —researcher Jean-Loup Faulon reverse-engineered themolecular structures of 800 drug compounds,proving that molecular descriptors were a secure repre-sentation for patentable chemicals as proposed by theNational Institutes of Health for its plannedPubChem database.

Technology partnerships

RESEARCHER HAL MORGAN, a long-time collaborator withCRADA partner Goodyear, shows off the TripleTred™ tire, ahome-run product for Goodyear. (Photo by Randy Montoya)

More than 60 teachers from elementary, middle, andhigh school participated in a summer program as

part of a ground-breaking collaboration among UNM, San-dia, and APS on inquiry-based science teaching. Sixcourses were offered in various content areas with graduatecredit provided for all participants, enabling many of themto meet specific “No Child Left Behind” requirements. Fivelocal educators attended a workshop on inquiry-based sci-ence teaching with the Golden Apple Foundation in prepa-ration for bringing it to Albuquerque in 2006.

Significant improvements were implemented in 2005 tostreamline the annual Student Internship Program MassSign-Out process. This process enabled more than 520students to separate from Sandia and the summerinternship program by visiting just one location. Intern-ship program staff worked with Records Management,Treasury/Travel, and the Badge Office to provide a greatlysimplified sign-out process, eliminating the need for theintern to physically visit each location. The process has ledto significant time savings and reduced effort to the serviceproviders involved.

The process of promoting employees from non-exempt toexempt positions was reengineered during a Kaizen Event.This was done to improve the way Sandia evaluates andpromotes its non-exempt employees to exempt staff,while providing line organizations with ownership of thisfunction. The appropriate checks and balances were addedto ensure administration of a fair and unbiased Fair LaborStandards Act-compliant process.

The Sandia Corporate Mentor Program celebrated its 10thyear in 2005. The program, which launched in 1995 with68 participants, had 936 participants in 2005, demon-strating that mentoring continues to be a powerful andeffective development tool. Last summer the program wasrecognized for two best practices in mentoring amongLockheed Martin enterprises. Two SAND reports have beenpublished about the model program, which earned a GoldPresident’s Quality Award in 2003.

Enhancements have been made to the “get people” systemto make it easier for job applicants to apply online. Theeducation screens were reduced from seven to one, and thesystem now uses terms commonly used by industry jobsearch sites. Feedback from applicants show that theyagree the system is easier to use. The speed, functionality,and interface for managers were greatly enhanced, too.These are just a few of the efforts that are helping the Labshire the best possible candidates.

Employee and Labor Relations Dept. 3011, along with sev-eral management partners across the Labs, signed collec-tive bargaining agreements with the Metal Trades Coun-cil, Office and Professional Employees InternationalUnion, and the Security Police Association. Through theagreements, management and more than 1,000 union-rep-resented employees will continue to work together toachieve mission critical goals.

The annual Student Internship Symposium and Career Fairlast August provided real-world experience for the morethan 225 interns who made presentations on theirresearch activities. The symposium is the culminating eventof the Student Internship Program, bringing togetherinterns, technical staff, mentors, management, and repre-sentatives from industry and academia. This high-energyevent included more than 800 attendees who participated

in numerous activities including a graduate opportunitiespanel where Labs President Tom Hunter spoke.

Our writers, editors, designers, videographers, and printersplayed a significant role in bringing recognition toSandia, its programs, and its people in 2005. Our prod-ucts communicated the Labs’ important work and broughthome to Sandia some 100 awards, including high honorsin PRSA Cumbre, Society of Technical Communication,Lockheed Martin’s Communication Excellence, and AuroraFilm and Video competitions. The Labs’ in-house printshop, with its state-of-the-art digital printing capabilities,contributed by printing many of the winning materials,from publications and posters to brochures and displays.Members from all the Center’s organizations worked

Integratedenabling services

Security




closely with White House communications staff to makethe August 2005 visit by President Bush a notable commu-nications success. (3600)

Recreating a “Learning Organization,” a major Sandiainitiative begun by the Strategic Education Committee,chaired by Executive VP John Stichman, got off to a solidstart with the allocation of 32 developmental hours for allSandia employees. The intent is to help Sandia employeesaugment their education relative to Sandia’s core missionareas. The funding covers time to attend a wide variety ofeducational experiences that fall outside an employee’s nor-mal work assignment, but within the Sandia mission space.

Health and benefit programs enable Sandia to attract andretain an exceptional workforce. HBE provides accessibleworkplace preventive, behavioral, medical services, andcompetitive benefits, deploying short and long-term costcontainment strategies in an era challenged by escalatinghealth care costs. The Disease Risk Management Clinic(DRMC) provides health services for employees with dia-betes, hypertension, hyperlipidemia, and obesity. In Octo-ber 2004, DRMC had 717 participants, increasing to 1,426participants as of September 2005. The Benefits Depart-ment provided new benefit plans that promote employeeconsumerism.

Center 3800 was responsible for planning and implement-ing all necessary changes for successful transition to thenew Labs structure in June 2005, while ensuring thorough,clear communication. A cross-organization team and func-tional area leads assured an efficient and effective transi-tion. Various information systems, policies, and proce-dures were affected by the change. The use of changemanagement techniques improved the communicationflow and minimized the impact to line organizations. Pro-ject management tools were successfully used to plan,track, communicate, and complete actions on time andaccording to executive expectations.

The Sandia Wi-Fi Project Team led three limited-area pilotdeployments, making Sandia the first facility in thenuclear weapons complex to deploy production wirelessnetworks in a limited area. The team also deployed wire-less networks in 13 buildings outside the tech areas at San-dia’s Albuquerque and Livermore sites. The wi-fi team isproviding significant leadership within the complex bysharing experiences and results with the other complexfacilities; the experience gained at Sandia may demon-strate that new technologies such as wi-fi can be usedthroughout the complex. (4300, 8900)

The Technical Library initiated a change in the MARCstandard for library cataloging in the US to the Libraryof Congress. This change includes historical security classi-fication change information in the MARC standard. TheLibrary of Congress accepted this change for immediateuse; it was published in the October 2005 MARC 21 Edi-tion. The change is also reflected in the Library of Con-gress MARC documentation.

The Portability pilot introduces ready network access formobile devices in select offices, laboratories, and meetingrooms around the Sandia/California site. Individualsemployed at any Sandia site can — without requesting spe-

include the Microsystems and Engineering Sciences Appli-cations Complex (MESA), the Center for Integrated Nan-otechnologies Core Facility (CINT), and the Test Capabili-ties Revitalization project. The program continues toreceive award recognitions for being the first laboratory inthe DOE complex to have a certified Earned Value Man-agement System in place to measure performance,improve efficiency, and reduce costs on large constructionprojects. (10800, 10200)

Sandia’s Energy Management Program continues toensure that utility systems are reliable and efficient,while conserving resources as much as possible. The pro-gram strives to integrate and institutionalize energy effi-ciency into planning, design, construction, and opera-tions, with excellent results. Last year, electricalreliability was 99.993 percent, exceeding the industrystandard of 99.982 percent. The program has alsoexceeded DOE’s 2010 goal of improving energy use inoffice buildings by 35 percent (relative to 1985 levels).Sandia has already reduced energy use in these buildingsby 39 percent. (10800)

Custodial Services Dept. 10848 continues to providegood customer service to the line at minimal cost. Thegroup was nominated for seven team awards and twoindividual awards at last summer’s fourth annual Operat-ing System 1 Users Group Symposium. The team tookhome three trophies from the ceremony: Best Program,Best Audit, and Best Cleaning Industry Safety Program.The group received the Green Certified Award and hasgone more than 15 months without a single lost workday due to an on-the-job injury. (10800)

Supplier Profile Management (SPM) was implementedwith the 11i10 Oracle upgrade. This enhancement imple-mentation to the iSupplier portal product was an intensiveeffort that required representation and participation fromProcurement, Accounts Payable and Supplier Profile man-agement. SPM enables the supplier to securely (electron-ically) register with Sandia through our external webpage. The benefits include more accurate address and con-tact information, greater source selection capability basedon classification and product/service definitions, andenhanced reporting capability.

A corporate-wide need was identified to develop a method oftracking Sandia business travelers. In February 2005, Treasuryand Travel Services Dept. 10507 developed a system to tracktravelers in case of emergency, replacing various home-grown systems. Enterprise Information Systems Developmentand Support (4524) created the Travel Information System, aone-stop solution allowing individual departments, as well asseveral support organizations, to identify travelers in needduring emergency situations. (10500, 4500)

Thanks to cooperation throughout the laboratories, cor-porate tax employees (10500) with the assistance of theOracle NMGRT programmer (4500) gathered informa-tion for additional deductions for New Mexico GrossReceipts Tax. The corporate tax team filed for this $3.5million refund. This refund was applied against our cur-rent year corporate tax liability of $62.5 million, whichlowered our overall tax liability to approximately $59million. The external corporate tax expense is recoveredthrough internal tax loads. This effort resulted inwinning an employee recognition award for the team.

Some 47,000 benefits plan documents (or nearly 1.6 mil-lion pages that would have been delivered in paper) weredelivered electronically. In FY05 alone, this saved about190 hours in the Sandia mail room, $50,000 in paper andprinting, and these savings do not include the environ-mental impact of eliminating 1.6 million pages of paperfrom the environment. We would like to believe there isa grove of trees somewhere because of these efforts.

Integratedenabling services

cial support — plug in their properly regis-tered, portable computing devices to des-ignated ports to access desired SRNresources. We developed software, policy,and procedures to support a satisfactoryuser experience, while adhering to funda-mental security principles. (8900, 4300)

The Training and Development Team inHuman Resources Dept. 8522 partneredwith an advisory team of senior managersto address the expected high rate of attri-tion of senior managers and directorsand the potential loss of their collectiveknowledge. Working with an externalconsultant, the team developed experien-tial learning modules to accelerate thedevelopment of future leaders. Topicsinclude: self-awareness and feedback;interpersonal communications; coaching;difficult conversations; transition manage-ment, ambiguity, and risk; decision-mak-ing and delegation; global vision, strategicthinking, and strategic planning. (8500)

Sandia Procurement Center 10200 spenttwo years establishing its ISO 9001:2000 system. The ISO sys-tem provides the organizations with a framework to focus onmajor processes and customer service, thereby increasingtheir value to Sandia and continually improving their perfor-

mance. In June 2005 an outside auditor visited Procurementand conducted a six-day audit of the ISO system. The auditorwas impressed, and 10200 became the first procurementgroup in the DOE/NNSA complex to earn ISO 9001:2000 cer-tification.

In support of DOE’s I-MANAGE financial implementationproject, Sandia redevel-oped its standardaccounting and reportingsystem — or STARS —application to satisfy allDOE requirements includ-ing sending specified dataelements on a monthlybasis and rewriting thefinancial reporting systemto enable monthly report-ing in DOE formatted data.This includes the cross-walk between the old(alphanumeric) and thenew (numeric) Budget andReporting numberingscheme. The changes posi-tioned Sandia to supportthe new DOE budgetingsystem (due out in Octo-ber). (10700, 10500, 4500)

Sandia’s construction pro-gram had another banneryear in FY2005, adding120,000 square feet ofspace to support new mis-sion work. Projects underdesign or construction

FACILITIES COMPLETED a discussion draft of the Long-Range Development Plan for the Albu-querque campus. The document is Sandia’s first comprehensive vision to guide campus devel-opment through the mid-21st century and create the “Lab of the Future.” To meet short-termspace needs, Sandia has awarded two contracts to lease more than 180,000 square feet ofspace offsite. Almost 1,000 people will be relocated, freeing up space onsite that can bebrought into the Limited Areas to help meet the critical classified space crunch facing manymission customers today. (10800, 10200)

CONSTRUCTION OF BLDG. 929 (above) was completed and the building wasoccupied by the Biological and Microfluidic Science group at the California site lastFebruary. The 22,974 sq. ft. building provides office and reconfigurable space forsome 70 researchers and staff, three conference spaces, two multi-use light assem-bly labs, and a central break room. The facility was Sandia/California’s first Institu-tional General Plant Project and was designed, constructed, and ready for occu-pancy in 12 months at a total construction and equipment cost of $4.7 million.

IN A KEY STEP advancing “operational excellence,” Sandiadeployed the Integrated Laboratory Management System at theLab level and within all the strategic management units. Docu-mented management systems that implement the five functionsof the Corporate Work Process were developed and deployed.Positive impacts on performance are expected through the sys-tematic anticipation and resolution of problems, as well as pro-viding assurance of effective performance and risk managementto our customers and stakeholders.

(Continued from preceding page)

MAKING HYDROGEN using thepower of the sun — Sandia

researcher Rich Diver works at asolar furnace, the energy source

that will drive his simple two-stepthermochemical process for split-

ting water into its constituenthydrogen and oxygen atoms. Theprocess will use a device of Rich’s

own invention; he calls it theCounter Rotating Ring ReceiverReactor Recuperator — or CR5.

(Photo by Randy Montoya)


2006 Labs Accomplishments

Documents

Transcript of 2006 Labs Accomplishments