Lab Accomplish 2009

This year’s Labs Accomplishments publication recognizessome of Sandia’s best work during 2008, as submitted bycenter offices and selected by division offices. Each citationis followed by the center numbers of centers that contributedmost directly to the effort described.

An acronym after each accomplishment indicates whichof Sandia’s strategic management units (SMUs)or strategic management groups (SMGs) the workmost directly supported. The SMG/SMU acronyms are:

NW: Nuclear Weapons SMG & SMUITS: Integrated Technologies & Systems SMGDS&A: Defense Systems & Assessments SMUER&N: Energy, Resources, & Nonproliferation SMUHS&D: Homeland Security & Defense SMUST&E: Science, Technology, & Engineering SMUIES: Integrated Enabling Services SMU

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 • Livermore, Calif. 94550Tonopah, Nevada • Nevada Test Site • Amarillo, Texas

Carlsbad, New Mexico • Washington, D.C.

Nuclear weapons engineering . . . . . . . 3

Engineering sciences . . . . . . . . . . . . . . 3

Product realization . . . . . . . . . . . . . . . 4

Remote sensing . . . . . . . . . . . . . . . . . . 4

Military programs . . . . . . . . . . . . . . . . 5

Energy . . . . . . . . . . . . . . . . . . . . . . . . . 5

Homeland security . . . . . . . . . . . . . . . . 6

Global security . . . . . . . . . . . . . . . . . . 6

Bioscience . . . . . . . . . . . . . . . . . . . . . . 7

Microelectronics & microsystems . . . . . 7

Computing & information sciences . . . . 7

Materials . . . . . . . . . . . . . . . . . . . . . . . 8

Pulsed power . . . . . . . . . . . . . . . . . . . . 8

Partnerships & alliances . . . . . . . . . . . . 9

IT, networks, & facilities . . . . . . . . . . . 10

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

Human resources . . . . . . . . . . . . . . . . 11

Supply chain . . . . . . . . . . . . . . . . . . . 11

Governance, leadership,

& management . . . . . . . . . . . . . . . 11

Community involvement . . . . . . . . . . 11

Sandia National LaboratoriesPage 2 • Sandia Lab News

Bill Murphy • Lab News EditorJohn German • Labs Accomplishments Editor

Michael Lanigan • Labs Accomplishments Production

Inside . . .

Sandia researchers Jeff Gruda (1524, left) and Jim Phelan (6418) use Sandia’s Visualiza-tion Lab in the Joint Computational Engineering Lab to examine results of a computersimulation that models the effects of an explosion on an aircraft fuselage. The simula-

tion was conducted under NNSA’s Advanced Simulation & Computing program forthe Transportation Security Administration. The research is helping develop a scientificbasis for aviation security requirements. See page 6. (Photo by Randy Montoya)

Sandia and StirlingEnergy Systems seta new solar-to-gridsystem conversionefficiency record byachieving a 31.25percent net efficiencyrate on a Stirling dishsystem at Sandia.See page 5.

Cover photograph by Randy Montoya

Page 3Labs Accomplishments • February 2009

Nuclear weapons engineeringSandia/California infrastructure and weapons groups sup-ported a study by the Institute for Defense Analysis (IDA)that evaluated the costs, savings, risks, and benefits ofsix alternatives for Sandia/California site infrastructureoperations. Among the alternatives were operating “as is,”merging some operations with Lawrence LivermoreNational Laboratory, and moving the nuclear weapons mis-sion to Sandia/New Mexico. IDA determined that continua-tion of current operations at Sandia/California meets mis-sion requirements and found no compelling costs basis forother alternatives examined. (8000, 10500) NW

Security & Use Control Assessment Dept. 12334, in con-junction with Centers 2100, 6300, and 6400, delivered twoend-to-end simulations of integrated security and use-control design principles. Three tools were brought intothe Virtual Deliberate Unauthorized Use Assessment Facility(VDAF) to accomplish the simulations: a force-on-forceanalysis software tool, a close-quarters battle software toolusing augmented reality, and a haptics interaction tool formanipulating CAD models. This work sets the stage for real-time analyses in the VDAF. (12300, 2100, 6300, 6400) NW

Sandia’s Systems Integration Technical Support Center 500has provided the leadership allowing the first integratedscience, technology, and engineering (ST&E) planningacross NNSA Defense Programs. The products include adetailed synthesis and analysis of more than 20 extantplans, a short summary of the breadth of work, and aclassified integrated description of work being done — all critical for ensuring an ST&E base for the nation as itmoves into an uncertain future. (500) NW

Using the nuclear weapons risk-based perspectives providedby the Sandia Integrated Life Cycle Surety team, strategiesfor improving the security of the nuclear weaponsstockpile were created. These strategies set forth a range ofpotential improvements in both physical security andweapon security features that could reduce the security riskof the stockpile. They will form the basis for Sandia partici-pation in the development of a national surety strategy.(600, 12300, 8200, 6100, 2100, 200, 5600) NW

Two simulations of integrated security and use control allowreal-time analyses in the Virtual Deliberate Unauthorized UseAssessment Facility (VDAF).

operational for all DoD operations and DOE production.CMS supports the B61, B83, W80, and W84 weapon systemsand the Code Enabling Switch. (2100, 2900, 5600, 8200,12300) NW

The Concurrent Design and Manufacturing (CDM)Program delivered 57 different component lots for eightdifferent technology areas in FY08. The 57 componentlots totaled 18,124 units delivered to the stockpilethroughout the year. CDM achieved a customer deliveryperformance of 96 percent. Completed component lotsincluded explosives components, magnetics, neutrongenerator timers, switch tubes, power sources, andmicroelectronics. (2500, 2700, 1700, 12300) NW

Sandia and Honeywell FM&T completed fabrication of anintegrated prototype of an optical initiation firing sub-system for weapon system applications. The prototype ispackaged in a form and volume appropriate for weaponapplications and integrates the laser system, firing controlelectronics, built-in test capability, and functional energy-interrupting elements to accommodate unique-signalsafety systems. This optical initiation project seeks toenhance safety by initiating detonators with a uniquehigh-energy laser pulse and replacing traditional detonatorcables with nonconductive fiber optics. (2600, 2100, 2400,1100, 1700, 1800) NW

Minuteman III flight test GT-194-1 was launched fromVandenberg Air Force Base on Aug. 13, 2008, carryingtwo W78/Mk12A Joint Test Assembly (JTA) reentry vehicles— a high-fidelityJTA5 and an instru-mented JTA6. Bothreentry vehicles trav-eled approximately4,200 miles, hittinga predetermined tar-get in the vicinity ofIlleginni Island atthe Ronald ReaganTest Site in thePacific. The uniqueflight allows fordirect comparisonsof the high-fidelityand instrumentedJTAs’ performancesthrough the flightenvironments. (2100, 2900, 8100, 12300) NW

Sandia made substantial progress in NNSA-directedtransformation of stockpile evaluation, supportingenhanced confidence in annual assessments. In-flighttesting, preflight temperature conditioning, expandedcoverage oflaunch andrelease parame-ters, and newinstrumentationprovided dataand validatedstructural modelsin rarely exploredregimes. Labora-tory testing incor-porated vibrationenvironments,combined tem-perature studieswith signal variations, and employed new classified analy-sis. Expanded component evaluation programs were inte-grated into system plans, and quantification of marginsand uncertainties and predictive models were employed toforecast performance. (2900, 2100, 8200, 2500, 2600, 2700,1500, 1800) NW

The final flight test of a gravity bomb weapon contain-ing special nuclear materials occurred at the Tonopah TestRange on July 22, 2008. A Sandia-Air Force test team suc-cessfully delivered a B61-11 to a target from an altitude of18,000 feet. A subterranean mining operation reachingdepths of more than 20 feet retrieved the test article forpost-test analysis, which confirmed nominal (expected)system performance. (2900, 2100, 4200) NW

B83 Development Joint Test Assembly-1B test atthe Tonopah Test Range

The W87 Joint TestAssembly (JTA) teamdelivered to NNSA thefirst JTA4 productionunit on schedule. Thisunit was later launchedaboard a Minuteman IIIintercontinentalballistic missile — theculmination of a five-year multiagencyprogram that includedSandia, Savannah RiverSite, Kansas City Plant,Pantex, Y-12, LawrenceLivermore NationalLaboratory, and the USAir Force. The JTA4 isan advanced telemetrysystem that collectsDOE and DoD datathat will be used forsurveillance of theW87/Mk21 warhead.(1700, 2500, 2600, 2700, 2900, 5300, 8200, 12300) NW

The Qualification Alternatives to the Sandia Pulsed Reactor(QASPR) team combined theory, experiment, and advancedsimulation and computing codes to model the effects offast-neutron pulses on the gain of silicon transistors.This key milestone demonstrated that the QASPR method-ology could beused to qualifySandia compo-nents in theabsence of fast-burst reactor test-ing. The predicteddevice response,with quantifiedmargins of uncer-tainty, was foundto be an excellentmatch to the exper-imental resultsgathered prior to the closure of SPR-III. (1100, 1300, 1400,1500, 1700, 2100, 5300, 6300, 6700, 8000, 12300) NW

Sandia designed and MESA fabricated the “Eiger” radiation-hardened, structured, application-specific integratedcircuit, a user-configurable platform with function hard-wired on the chip during the last stages of fabrication.Eiger’s open archi-tecture enablesdesign flexibilityand reduces non-recurring engi-neering and devel-opment costsboth for newdesigns and obso-lescent parts. Itwas specificallydeveloped forembedded applications with features to minimize powerconsumption, static current, and photocurrent. Eiger tar-gets Sandia’s nuclear weapon mission with potential forsuch applications as deep-space missions and down-holeinstrumentation. (1700, 2100, 5300) NW

The Code Management System (CMS) for Use Control wasimplemented at the Pantex Plant. CMS significantlyimproves the throughput of Permissive Action Link(PAL)-equipped weapons at the Pantex Plant. The firstunit was processed on May 15, 2008, and CMS now is

W87 JTA4 First Production Unit

Comparison of predicted responseand experimental results gatheredprior to closure of the Sandia PulsedReactor (SPR-III).

Eiger rad-hard circuit

The B83 Development Joint Test Assembly-1B (DJTA-1B)was successfully flown at the Tonopah Test Range in July2008. DJTA-1B provided critical data for verification and val-idation of computational simulation analyses for the B83program. This newly designed high-fidelity flight test unitflew a unique profile and met all test requirements includingan NNSA Level 2 milestone. To meet the flight test window,DJTA-1B required an aggressive schedule with close coor-dination among Sandia, Lawrence Livermore National Lab-oratory, Kansas City Plant, Pantex, NNSA, and the Air Force.(1500, 2600, 2900, 8200) NW

Minuteman III flight test in August 2008allowing comparisons of performances ofW78/Mk12A Joint Test Assemblies

Shaker table at the Weapons Evaluation TestLaboratory for mechanical preconditioning

B-2 bomber delivers B61-11.

Engineering sciencesThrough Engineering Campaign funding, EngineeringSciences Center 1500 has developed a test capability tosimulate flight conditions of launch through reentryinto a single ground-based test. The combined environ-ment test capability, named Superfuge, has demon-strated synergistic effects for several test units whenenvironments such as vibration and acceleration wereapplied simultaneously. These effects were significantand indicate the need for such testing to capture correctsystem response. Also, the ability to perform marginassessment under more realistic flight conditions hasbeen realized with this new capability. (1500) NW

A closely coupled effort between the weapons and sci-ence and technology communities has resulted in amultidisciplinary effort to develop a high-fidelity, three-dimensional predictive modeling and simulationtool for neutron tube performance. This effort isfocused on capabilities addressing design, qualification,and issue resolution. As part of an Advanced Simulation& Computing Level 2 milestone, Sandia has completedthe first three-dimensional neutron tube plasma trans-port simulations, enabling qualitative assessment ofcritical performance parameters. (1100, 1400, 1500,2700, 9300) NW


The W76-1/Mk4A First Production Unit was delivered inSeptember 2008. This milestone represents the most signif-icant product delivery by the nuclear weapons complex inmore than a decade, made more significant because LosAlamos National Laboratory was able to certify the war-head without an underground test. The delivery required

significant contributions from across Sandia and was madepossible by teaming with partners at Los Alamos and thenuclear weapons complex production agencies and work-ing effectively with Sandia’s NNSA and Navy customers.(2100, 1300, 1500, 1800, 1700, 5300, 2400, 2500, 2700, 2800,2900, LANL, production agencies, NNSA, US Navy) NW

Developing and implementing the Realize ProductSubSystem (RPSS) of the Nuclear Weapons StrategicManagement Unit was a significant undertaking, affectingthe way thousands of people perform their jobs. The RPSSintegrates thousands of requirements and practices intoapproximately 130 mandatory procedures. The newlyformed, director-level Realize Product Council ensuresleadership engagement and continued sustainment andimprovement of the system. The RPSS simplifies Sandia’sapproach to meeting requirements, improves consistencyand reduces redundancy, accelerates learning for newemployees, and provides a baseline for communication,training, and continuous improvement. (Supported by allNW centers) NW

Significant progress was made toward the use of one uni-versal three-dimensional computer-aided design (CAD)model for the MC4532 neutron generator project. Thisconcept will allow increased utilization of one model forall stakeholders, including design, manufacturing, andanalysis, throughout the design life cycle. A top-downmodeling approach was used by specifying design criteria,including parameterization, at the top-level assembly andpassing those criteria down through the model structure.Because of this approach, incorporation of design changeswas simplified, resulting in significant design-to-analysiscost and schedule savings. (1500, 2400, 2700, 2900) NW

Responsive Neutron Generator Product DeploymentCenter 2700 in July 2008 became the first public-sectororganization to be awarded the Shingo Prize for Opera-tional Excellence. The Shingo Prize recognizes excellencein using lean principles to achieve operational excellenceand consistent business results. Center 2700 received theprize for demonstrated results in cost reduction, quality,and productivity by using lean tools; integrating the neu-tron generator life cycle from science, through develop-ment and production, to sustainment; and affecting a cul-ture change toward lean thinking across the organization.(2700) NW

As part of the Tech Area 55 (TA-55) upgrade at Los AlamosNational Laboratory to support manufacturing require-ments, Sandia developed a discrete-event simulation forplutonium processing to analyze process and transporttimes within the machining and foundry areas, as well as athree-dimensional visualization to demonstrate proposedmaterial transport scenarios within Wing 300. Both thesimulation and 3-D visualization were used to evaluateproposed part transportation scenarios within the facility.The results of Sandia’s Wing 300 production analysis wereused to make recommendations to NNSA concerningfacility upgrades. (6400) NW

The MC4082A Power Supply Product Realization Teamconcluded that massive updating was required for theMC4082A powersupply drawingset. After sixmonths, morethan 2,700person-hours,intense require-ments mapping,and 331 drawingchanges, theMC4082A was

manufactured to a new set of 45 drawings and subse-quently submitted for final product acceptance, withno errors, issues, or findings. (12300, 2500) NW

A reliability assurance methodology was developed thataddresses the need to obtain highly reliable nuclearweapon components from small production builds.The method combines fault tree and expert critique toidentify a manageable number (typically about 20) of fataldefects that must be prevented, and identify controls thatmust be implemented. The method, which is both efficientand effective, focuses attention on what is essential andhelps resolve conflicts. It has been successfully applied toreliability assurance of energetic components. (12300) NW

A Sandia-invented, power-free leak tester was imple-mented at Pantex. The Lightning-Immune Leak Tester iscompact and easy to use and meets leak test requirementswithout the useof AC power,which enablesweapons test-ing to continueeven duringlightning warn-ings. Recently amoisturesphere wasincorporated,enabling effi-cient screeningof moisture levels in weapons for component reuse deci-sions. Since implementation, significant savings (greaterthan $10,000 per month) and reduced processing timescontributed to a recent effort being completed two monthsahead of schedule. (12300, 1800) NW

Sandia science, technology, and product realization exper-tise enabled the development, qualification, and deliveryof the first optical transceivers for space applications.Sandia worked in concert with Peregrine Semiconductor,ULTRA Communications, and n-Light Corporation todeliver the final products. Once on orbit, each opticalchannel of these radiation-hardened devices will providelow-noise, 2.5 gigabit-per-second, bidirectional transmis-sion of critical sensor data to onboard processors that con-figure data for satellite downlink. This revolutionary, high-bandwidth data processing capability is a key enabler fornext-generation space-based remote sensing systems.(5700, 5300, 5500, 1800, 1700, 1500, 12300, 10200, 2400,Peregrine Semiconductor, ULTRA Communications,n-Light Corporation) DS&A

Remote sensing

Product realization

Working closely with NNSA and the US Air Force, a jointSandia/Los Alamos National Laboratory team develops andlaunches satellite pay-loads supporting thenation’s nonprolifer-ation and treaty veri-fication programs.Since 1983 the teamhas launched nucleardetonation detectionpayloads into orbit onthe Global PositioningSystem (GPS) satellite.This year the teamlaunched three pay-loads on GPS, includ-ing the 50th payloadin March 2008. Thisprogram involveshundreds of scientistsand engineers fromSandia and LosAlamos and is thebackbone of the nation’s nuclear detonation detectionsystem. (5700, 5500, 5300, 2600, 1700) DS&A

Sandia and Rockwell Collins are increasing the functional-ity of unmanned aerial systems (UASs) by developingminiature aluminum nitride microelectromechanicalsystem filter banks for spectrally aware electronicsystems. Microresonator designs and fabrication processesdeveloped at Sandia enable low-loss filters to operate overa wide frequency range in a small size (three squaremillimeters of die area). Continuing advancement of thistechnology will enable a new class of spectrally awareelectronic systems with massive reductions in size andpower consumption. (1700) DS&A

Sandia and Teledyne Imaging Sensors have developed andproduced 2,000-by-2,000-pixel focal plane arrays. Thesefocal planes, BTB-2K, are among the first with onboardanalog-to-digital conversion of electrical signals and repre-sent a significant milestone in achieving higher levels ofconversion efficiency. This technology advance will enable

greater sensitivity in signature collection, pushing the stateof the art for large area arrays. (5700, 5500, 1700) DS&A

To meet emerging treaty monitoring requirements, Sandia’sground-based nuclear explosion monitoring team hasdeveloped a system to produce realistic three-dimensionalmodels of theEarth’s seismicvelocity distri-bution basedon the tomo-graphic inver-sion of millionsof seismictravel-timeobservations.Calculations areperformed witha distributedcomputing plat-form based onthe Java ParallelProcessing Framework, providing a unique capability forthis community. The system utilizes a dedicated set ofmulticore servers, as well as desktop machines, enablingresearchers to exploit more than 200 processor cores.(5500, 5700) DS&A

A multidisciplinary engineering team identified architec-tural approaches to a national security space applica-tion. To explore the relevant trade space, the team adaptedestablished modeling and simulation capabilities, andcombined it with newly created application-specific mod-els. The modeling system was used to develop and refinean architectural solution to the specific problem. By com-bining Sandia’s inherent modeling and simulationstrengths with constellation-level system design skills,Sandia was able to explore critical trade space and identifypreviously overlooked options for solving critical nationalneeds. (5300, 5400, 5500, 5700) DS&A

Real-time high-consequence systems require fluid, terse,intuitive communications among team members to maxi-mize system performance. Extensive observation of on-going intelligence, surveillance, and reconnaissance (ISR)R&D activities at Sandia yielded evidence and theory show-ing how ISR systems harness human psycholinguistic

mechanisms to process situational context and missiongoals. This empirical research in real mission environmentsprovides original insights into ISR collaborative situationalawareness and reasoning. Results have been shared withoperations crews, managers, engineers, and policymakers,generating interest and accolades, and establishing a newdesign basis for future collaborative systems. (5500) DS&A

Sandia’s Strategic Plan states: “When we achieve our high-est goal, we are widely recognized as a national leader inpreventing technological surprise…” Technological sur-prise is defined as the unexpected development of a game-changing technology among potential adversaries. Sandia’sDefense Systems & Assessments Strategic ManagementUnit is developing methodologies to understand theoccurrence of such technologies. Critical to this method-ology is increased awareness and participation of the entirelaboratory. Biweekly seminars, drawing speakers fromthroughout and outside the Labs, stimulate and initiatethe cycle of understanding. DS&A

The Sandia “TriSAR” program is a multiagency, multi-corporation effort to develop a series of small, low-cost,high-performance space-based imaging radar systemsto supportlunar mis-sions to findice/water formannedspace flightto the moon.Sandia deliv-ered softwareand flight-qualifiedhardware ofthe DigitalReceiver andQuadratureWaveformSynthesizerto NASA andthe Johns Hopkins University Advanced Physics Laboratory.Time magazine named the NASA-sponsored LunarReconnaissance Orbiter (LRO) number three of the 100 topinventions for 2008. LRO is scheduled for launch in April2009. (5300, 5900, 5700, 1500) DS&A

The W76-1/Mk4A was certified without an underground test. The Lightning-Immune Leak Tester

The MC4082A power supply

Global burst detector system beinglaunched to medium Earth orbitfrom Cape Canaveral, Fla., onMarch 15, 2008.

Model of the Earth’s seismic velocitydistribution.

Lunar Reconnaissance Orbiter


Sandia provided modeling and simulation to assist the USMissile Defense Agency and US Navy in shooting downan errant satellite in February 2008. The Missile DefenseAgency asked Sandia to deliver in nine days the required“hit point” to prevent significant pieces of the satellitefrom reaching the Earth. The team delivered the calcula-tions and supported real-time assessment of the event atSchriever Air Force Base, Colo., where decisions were madethat a second intercept shot was not required. (5400, 1400,1500, 2900, 5500, 5900, 9300) DS&A

The Key Data Processor (KDP) is a custom microcircuitthat securely provides the next-generation cryptogra-phy mandated by the Joint Chiefs of Staff for all militaryGlobal Positioning System receivers. Sandia’s trusteddesign center pioneered numerous external interfaces and

processes to develop thisfirst major microelec-tronic product fabricatedin DoD’s IBM TrustedFoundry. Sandia demon-strated first-pass successwith the 130-nanometerKDP-III system, whichhas been seamlessly inte-grated into two receiverplatforms. Sandia nowhas generated a KDP-IVdesign on the 90-nanometer IBM process.(1700, 2600, 5600,12300) DS&A

for electric vehicle appli-cations. Sandia receivedthe Battery Power, Products,& Technology magazine’sInnova Award given tothe company “that hasshown a commitment toexcellence and is a lead-ing innovator in the bat-tery industry.” Sandia’sprogram also had thehighest aggregate score of21 Advanced Technology Development projects evaluatedduring the annual merit review of DOE’s Energy Efficiencyand Renewable Energy (EERE) Office of Vehicle TechnologiesProgram. (2500) ER&N

Sandia is part of a US-French team that successfully com-pleted the first-ever demonstration of hydrogen productionunder prototypic conditions from the sulfur-iodine cycle.Sandia developed a unique bayonet-type heat-exchanger/reactor to decompose sulfuric acid at 850˚C. Sulfur dioxideproduced by the Sandia section was used in the Frenchreactor to produce a heavy acid phase that was subse-quently processed by the General Atomics reactor to pro-duce hydrogen. It was the first demonstration of hydrogenproduction from the sulfur-iodine cycle at pressure usingengineering materials of construction. (6700) ER&N

DOE is investing as much as $24 million to develop solarenergy products that will significantly accelerate penetra-tion of photovoltaic systems in the US. The SolarEnergy Grid Integration Systems (SEGIS) projects willprovide critical research and development funding todevelop less expensive, higher-performing products to

enhance the value of photovoltaic systems to home andbusiness owners. Sandia will provide project managementsupport to these projects. (6300, 10200) ER&N

Sandia now supports the US Nuclear Regulatory Commis-sion’s Office of New Reactors in performing license application reviews (multiple plant systems and sites)for early site permits, design certifications, and combinedconstruction and operating licenses for the next round ofnuclear reactors in the US. Seventeen construction andoperating license applications for 26 new reactors alreadyhave been submitted to the NRC, with an additional sixapplications for nine reactors expected through 2010.(6700) ER&N

Sandia and Stirling Energy Systems (SES) set a new solar-to-grid system conversion efficiency record by achieving a31.25 percent net efficiency rate. In the SES system at Sandia,a solar dish generates electricity by focusing the sun’s raysonto a receiver, transmitting the heat energy to a Stirlingengine. The engine is a sealed system filled with hydrogen.As the gas heats and cools, its pressure rises and falls. Thechange in pressure drives the pistons inside the engine,producing mechanical power, which then drives a generatorand produces electricity. The efficiency rating achievementearned a Breakthrough Award from Popular Mechanicsmagazine. (6300) ER&N

In partnership with General Motors, Sandia completed afeasibility study of large-scale biofuel production in theUS. The study was uniquely constructed such that it con-sidered least-cost pairing of biomass resources and conver-sion technologies, dynamic ramp-up of large-scale biofuelproduction, and constraints with respect to feedstock avail-ability, land use, water requirements, energy use, and thebiofuels distribution network. A system dynamics softwareproduct, the Biofuels Deployment Model, was developed toquantify complex interactions and sensitivities within thebiofuel supply chain. (6300, 8100, 8300, 8600, 8900) ER&N

Military programs

Energy

General Atomics and Sandia are reducing the size, weight, and power requirements of a new synthetic aperture radar(SAR) system for unmanned aerial systems. The new Lynx II radar provides all-weather precision capability to detecttime-sensitive targets and offers a long-range, wide-area surveillance capacity. Following successful Lynx II field tests,the General Atomics Radar Systems director stated that the Lynx II could not have happened without Sandia. GeneralAtomics is to deliver 33 Lynx II radars in 2008 and 2009; the first six have been delivered to the Iraqi Air Force Intelli-gence, Surveillance, and Reconnaissance Program. (5300) DS&A

General Atomics and Sandia are reducing the size,weight, and power requirements of a new syntheticaperture radar (above) for unmanned aerial systems

A lithium battery undergoingtesting at the Sandia Abuse TestFacility

Chuck Andraka in front of the Stirling dish array at Sandia(Photo by Randy Montoya)

A multidisciplinaryteam from across theLabs completed Phase Iof the DARPA Strategi-cally Hardened Facil-ity Defeat Program,which seeks to developan end-to-end system todefeat deeply buriedstrategic facilities. Theteam achieved tenfoldimprovements in rockpenetration perfor-mance; developednew, high-accuracyalgorithms for subsurface sensing; and demonstrated anovel compact power system. When integrated in Phases IIand III, these enabling technologies will provide the long-sought nonnuclear strike capability to hold an adversary’smost critical assets at risk. Phase II has been awarded toadvance the feasibility demonstration system to anoperational concept. (5400, 6300, 5300, 1800, 10600, 12300)DS&A

Sandia supported eight missions in 2008 at the KauaiTest Facility (KTF) for the US Missile Defense Agency andUS military programs. Five missions were in support of theNavy’s BallisticMissile DefenseAegis program,two were in sup-port of the Army’sTerminal High-Altitude AreaDefense program,and one was insupport of a Navyfleet exercise. Theschedule for 2009shows the sameamount of activityat KTF. 2010 and beyond includes additional programswith the Army, Navy, and the University of Hawaii. (5400,2600, 1500) DS&A

The Key Data Processor IIIsecurely provides next-generation cryptography formilitary Global PositioningSystem receivers.

Strategically Hardened FacilityDefeat system deployment test

Dual launch from the Kauai Test Facility

Depiction of the Solar Energy Grid Integration Systems(SEGIS) concept

Oxide semiconductor/conjugated polymer compositescouple the environmental stability of the oxide with eco-nomical solution-based organic semiconductor processing,

attractive for low-cost hybrid photovoltaic devices. Sandiaresearchers discovered that ZnO/P3HT [zinc oxide/poly (3-hexylthiophene)] hybrid junctions improve in efficiencywith insertion of alkanethiol self-assembled monolayers.This observation is unexpected given alkanethiol’s electri-cally insulating properties. The alkanethiol interfaciallayer, however, increases the crystallinity of interfacialP3HT, increasing exciton diffusion length or hole mobil-ity, thereby outweighing the added electron-tunneling bar-rier. This discovery suggests a path to engineering higher-efficiency hybrid photovoltaic devices. (1100, 1800) ER&N

The Joint BioEnergy Institute (JBEI) became fully opera-tional at the Emeryville, Calif., location. The move wascompleted in July 2008and more than 100 peo-ple are working at thefacility. The first annualproject review by DOEoccurred in October andthe entire team receivedoutstanding feedbackon FY08 accomplish-ments. Scientists work-ing on the project pub-lished 15 peer-reviewedpublications, filed seven patent applications, and pre-sented their findings at 53 conferences. The project is onschedule to meet staffing and project milestones for FY09.(8600, 8300) ER&N

Sandia’s battery abuse research program is recognizedinternationally as the leading research center of its type

EmeryStation East in Emeryville,Calif., site of the Joint BioEnergyInstitute

ZnO nanorod array structures deposited from solution as theywould be for hybrid photovoltaic nanostructured devices


Sandia’s BioWatch Indoor Reachback Center (BIRC) beganfull 24/7/365 operations in support of the Department ofHomeland Security’s BioWatch program, an early warningeffort designed to detect trace amounts of biological mate-rials. BIRC’s role is to provide scientific modeling sup-port to decision makers responding to a public release ofa hazardous biological agent. BIRC’s extensive database offacility information and analytical capabilities enable teammembers to rapidly generate information that facilitatesemergency response, such as estimates of the size andlocation of the release. (8100) HS&D

After seven years of working in secret, Sandia was releasedfrom nondisclosure agreements with the FBI regarding aproject in which the Labs applied advanced microanalysistools, developed for nuclear weapons work, to determinethe distribution ofelements in anthraxspore materialsmailed in 2001 toseveral news mediaoffices and two USsenators. Highlydetailed analyseswere conducted onhundreds of samples,showing that thespore materials in theletters most likelycame from the samesource and that nochemical additiveswere used to makethe spores more dispersible. (1800, 5900) DS&A

The Precision Aim Team developed and fielded a system toprecisely identify, target, and disable internal compo-nents of an improvised explosive device (IED) whiledramatically reducing an operator’s time on target and pre-serving forensics evidence. The system is quicker, easier touse, and less expensive than existing systems and can beused by federal, state, and local emergency responders. Itcombines Sandia-developed technologies, including visual

tracking, pose estimation, stereo X-raytargeting, graphical model building,and model-based collision detection.(6400, 5900) NW

To assess the threat of onboard explo-sions from terrorist bombs, theAdvanced Simulation & Computingprogram produced visual assessmentsof airplane damage in response todetonations (see photo on page 2).Computational modeling offers simula-tion-based confidence for explosivethreats and myriad factors affectingstructural vulnerability that cannot bedetermined solely from empirical tests.Hydrodynamic blast models were linkedto finite-element structural-responsemodels to generate blast effects. TheTransportation Security Administrationwill use this work to revise requirementsfor future aviation security explosivesdetection technology. (6400, 1500,5400) HS&D

Sandia conducted the first systematic study of wide-arearestoration (tens of square miles, hundreds of buildings)following a large bioattack and guided government invest-ment in biorestoration technology and policy. This work,supporting the Department of Defense and Department ofHomeland Security collaborative Interagency BiologicalRestoration Demonstration program, determined the cur-rent state of science, technology, policy, and plans forwide-area biorestoration and identified key capability gapsto inform investment priorities. Sandia’s analyses alsohelped government agencies reach consensus on changesin biorestoration policy. (8100, 6300, 1500) HS&D

A new “cellular observatory” enables novel imaging oflive cells to unravel complex biological processes.Through the development of novel time- and frequency-resolved confocal microscopy, this instrument providesentirely new approaches for distinguishing multiplelabeled proteins in cells and for confidently identifyinginteractions of cellular proteins. Applications range fromenergy security to homeland defense and include the engi-neering of enzymes and organisms to produce biofuels andthe identification and mitigation of infectious diseasepathways. (8300, 8600) HS&D

EnergyDOE has committed to building 20 percent of the “FirstWall” for the International Thermonuclear Reactor Experi-ment (ITER), a €10 billion collaborative effort amongmany nations. Sandia is tasked with developing criticalmanufacturing processes and has successfully built andtested several First Wall qualification mockups intendedto measure the thermomechanical integrity of the beryl-lium-armored First Wall. The commercial manufacture ofFirst Wall structures is expected to be worth well in excessof $100 million to US industry. (8700, 8200, 1600, 1800)ER&N, ST&E

Aerial view of Yucca Mountain

On June 3, 2008, DOE’sOffice of Civilian Radioac-tive Waste Managementsubmitted the YuccaMountain RepositoryLicense Application to theUS Nuclear RegulatoryCommission. After athree-month review todetermine the complete-ness of the application, itwas docketed, officiallystarting the Yucca Moun-tain licensing process. Asthe Lead Laboratory forRepository Systems,Sandia was responsiblefor the development andpreparation of the post-closure component of thesafety analysis containedin the application and thedevelopment of theunderlying technicalbasis. (6700, 6300, 9500,10660, 10200) ER&N

Workers deliver the Yucca Mountain LicenseApplication to the Nuclear Regulatory Commis-sion office in White Flint, Md., on June 3, 2008.

A First Wall qualification mockup consisting of three 80 mmberyllium tiles bonded to a copper alloy stainless steel basewas fabricated and tested by Sandia. The mockup successfullypassed thermal cycle testing for the International Thermo-nuclear Reactor Experiment (ITER).

Homeland security

Elemental distributions in a sporefrom a letter mailed to a US senator

Sandia researchers (left to right) Nerayo Teclemariam, Nate Gleason (both 8125),and David Franco (8114) review facility plans from a major US airport. Suchmaterials, combined with decades of research, help BioWatch Indoor ReachbackCenter (BIRC) team members make accurate predictions for facility owners thatcan help secure and protect their buildings. (Photo by Randy Wong)

Cellular observatory image of a single, live macrophage cell exposed to lipopolysaccharide (LPS) endotoxin labeled with adye. The unique red spectrum and lifetime identify the region in the image where the endotoxin has entered the cell incontrast to the other signals that result from natural fluorescence.

Sandia’s International Physical Protection Programsupported NNSA Global Threat Reduction Initiativeefforts to protect international radiological sites, securenuclear materials at research reactors, and providephysical protection for the BN-350 spent nuclear fuelin Kazakhstan. The program began work to protectlarge radiological sources in Uganda, Tanzania, Tunisia,Mongolia, Romania, and Uruguay. It also completedphysical protection upgrades at research reactor sites inChile, Jamaica, Vietnam, and the storage location forthe BN-350 spent fuel that contains significantamounts of highly enriched uranium and plutonium.(6700) ER&N

A formal five-day training course on ControllingLaboratory Bio Risks has been developed. The courseuses the mockBiosafety Level 2training laboratorylocated in Sandia’sInternationalPrograms Buildingto train studentsthrough a combi-nation of lectureand hands-ontraining. To date,participants havecome from acrossthe United States and many countries. They haveincluded scientists, public- and agricultural-healthresearchers, laboratory directors, law enforcement, andpolicy makers who need to be informed about the latestdevelopments in lab biosecurity, bio safety, andcontainment-laboratory design. (6700) ER&N

A cross-lab team sponsored by Institutional Develop-ment Center 12100 completed a set of in-depth techni-cal studies to assess the implications of a renewedcall for ratification of the Comprehensive Test BanTreaty. The results of these studies provide a basis forlaboratory leaders to assert the need for US globalleadership in matters of a nuclear nature, options tocontinue to provide a credible nuclear deterrent for theindefinite future, and comprehensive monitoring andverification solutions. (12100, 240, 5900, 5700) NW,ER&N, DS&A

Global security

Egyptian scientists in a traininglaboratory

Emerging national security challenges require techniquesfor extracting insight from large and complex data collec-tions. Researchers from across the Labs are teaming todevelop novel analysis and visualization techniques andto investigate new computer architectures for such problems.An early result of the Networks Grand Challenge LDRD was aprototype system for studying cyber attacks using advancedalgorithms and tools. In a related development, Sandia hasobtained one of the first “massively multithreaded” super-computers,ideally suited for complex data analysis appli-cations. (1400, 8900, 5600, 5900, 9300, 9500) NW


An LDRD research team from Cryptography & Informa-tion Systems Surety Dept. 5635 has developed a newhash algorithm and submitted it to the National Instituteof Standards and Technology for consideration as a newnational standard. Hash functions are extremely impor-tant for authenticating data. Weuse one every time we make anInternet purchase, for example.Recently the current standardfamily of hash functions used forInternet authentication waspartially compromised by Chinesemathematicians, prompting thecall for a competition to find abetter solution. Sandia’s entry isexpected to be highly competitive.(5600) DS&A, ER&N

Sandia convened a meeting inWashington of 85 leaders fromindustry, government, andacademia to confirm the need forcomputation-based engineering(CBE) as a tool for US competi-tiveness. Keynote addresses byLabs Director Tom Hunter andNational Academy of EngineeringPresident Charles Vest, as well as

talks by Sen. Kay Bailey Hutchison (R-Texas), former DOEUnder Secretary for Science Ray Orbach, and NationalScience Foundation Director Arden Bement, were followedby discussions of collaborative ways to overcome barriersto CBE adoption throughout industry and government.(1, 1000, 1500) ST&E

Sandia is working with the US Nuclear Regulatory Com-mission (NRC) to assess and improve the design andimplementation of digital instrumentation and controlsystems, responsible for ensuring safe and secure opera-tions at power generation plants. Assessing these systemsis necessary to determine the risks associated with employ-ing them. Sandia also is helping the NRC ensure adequatecyber protection in nuclear digital safety networks, as thesenetworks may be subject to attacks that attempt to modifyconfigurations and disrupt safety functions. (5600, 6700)DS&A

Funded under DOE’s National SCADA Test Bed Program,Sandia released a new software tool, Advanced NetworkToolkit for Assessments and Remote Mapping (ANTFARM),that will aid energy utility owners in mapping and visu-alizing their control system networks. Making this toolavailable is a critical first step in meeting the North Ameri-can Electric Reliability Corporation’s critical infrastructureprotection standards. Sandia has made the source code anddocumentation available to all interested parties via anopen-source repository website under a no-fee, general-purpose license agreement. (5600) DS&A

Sandia exercised a set of risk analysis capabilities withenergy control system owners, operators, and stakehold-ers at its June 24, 2008, workshop “Cyber Attacks on Con-trol Systems: Evaluating the Real Risk.” As part of a projectfunded under DOE’s National SCADA Test Bed Program,Sandia has developed these risk analysis tools using athreat-to-consequence framework. The capabilities willallow Sandia to help owners and operators prioritize risks,focus limited resources on the most pressing securityissues, and build a business case for needed cyber securityimprovements. (5600, 6300) DS&A

Computing & information sciences

BioscienceThe Microscale Immune Studies Laboratory (MISL) GrandChallenge concluded at the end of FY08. Accomplishments ofthe MISL team include 14 papers published or manuscriptssubmitted, a recent Biophotonics International journal cover,eight technical advances, and several patents pending or inpreparation. In addition to these technical accomplishments,MISL has led to a strategic partnership with the University ofTexas Medical Branch (UTMB) and two funded NationalInstitutes of Health projects (one Sandia-led, one UTMB-led).(8600, 1700, 1800, 1400) ST&E

The MicroscaleImmune StudiesLaboratory (MISL)platform’s integratedflow cytometry andimaging capabilitieshave allowed, for thefirst time, measurementof kinase activity andtheir translocation inthe same populationof cells.

Microelectronics & microsystemsHy Tran (2541), MeghanShilling (2541), AndrewOliver (former Sandian), andAndre Claudet (2614) won a2008 R&D 100 award fordeveloping a Silicon Micro-machined DimensionalCalibration Artifact. Theartifact has an innovativethree-dimensional structuresuitable for calibration ofmesoscale measurementmachines that use optical,tactile, or a combination ofoptical and tactile measure-ment methods. It is madefrom a single-crystal siliconwafer, patterned and thenanisotropically etched toform dimensional features.The same artifact and geometri-cal features can be used to cali-brate vision-based dimensionalmetrology systems, touch-probe based systems, andhybrid metrology systems.(2500, 2400, 1700) NW The Silicon Micromachined Dimensional Calibration Artifact

A prototype system for studying cyber attacks provides anunprecedented ability to do scalable analysis for cyberdefense.

The Red Storm supercomputer aids in scientific discovery.

Co-architected by Sandia and Cray, the Red Storm super-computer is Sandia’s premier computing system. Withfunds from the Advanced Simulation & Computing (ASC)program, Red Storm was successfully upgraded to include38,400 processing elements through the introduction ofnew quad-core AMD Opteron processors. The peak process-

ing power of Red Storm rose to 284 trillion operations persecond, more than double its previous level. The systemremained operational throughout the upgrade period andsupported several Level 2 ASC milestones. It also is in thetop 10 of the TOP500 list, and there are now 30 Red Storm-like installations worldwide. (9300, 1400, 1500) NW

Sandia has developed a set of risk analysis tools that allow energy control system owners,operators, and stakeholders to prioritize cyber security improvements.


Density plot showing complex 3-D structures thatdevelop in the imploding plasma in Z

Two-dimensional bilayers, with electrons inone layer and holes in the other, are pre-dicted to exhibit quantum Bose-Einsteincondensation of excitons, which are usuallygenerated optically. Sandia fabricatedunique electron-hole bilayer semiconductorheterostructures to test this theory andquantified coupling between electron and holelayers using Coulomb drag measurements. Anincrease in drag resistance for a narrow barrierdevice at very low temperatures suggests pair-ing of electrons and holes into excitons. Thisis the first evidence that excitons can beelectrically generated in such systems.(1100, 1700) ER&N

Drawing of experimental geometry used toobtain shockless compression data on the newlyrefurbished Z

Sandia’s Thunderbird emblem patterned on a silica wafer coated with a pattern-able superhydrophobic coating. The patterned image is invisible until placed incontact with water. As the water covers the wafer, it adheres to the hydrophilicareas, revealing the Thunderbird image.

Konrad Thürmer (8656) with the scanning tunneling microscopy(STM) chamber and (at right) STM images of ice films. The abruptcontrast changes are ice surface steps of molecular height, whichhave never been imaged before. (Photo by Randy Wong)

Cross section of the refurbished Z machine

MaterialsManufacturing Science & Technology Center 2400 andHoneywell FM&T have developed an innovative processto manufacture composite housings for weapon use-control devicesand potentiallymany otherapplications.Composite hous-ings use fibers ina polymer matrixto provide anattractive combi-nation of highstrength and lowweight. Tradi-tional methodsfor making suchhousings arelabor-intensiveand costly. Thenew process,now enteringproduction, usesspecial moldingcompounds and foams to form complex internal featureswith fewer steps, resulting in a 60 percent time and costreduction. (2400, Honeywell FM&T) NW

Pulsed power

Knowledge of the structure of nanometer icefilms has remained elusive due to a lack ofimaging techniques. Electron microscopeshave failed because their electron beamsdestroy the ice, and the insulating nature ofice has limited the imaging capabilities ofscanning tunneling microscopy (STM) to oneor two molecular layers. Two Sandians, KonradThürmer and Norm Bartelt (both 8656),discovered how to image ice multilayersusing STM by extracting the electrons neededfor imaging from the valence band of ice. Thisapproach already has yielded new insights intowater-solid interactions at the nanometer scale.(8600, 1100) ER&N

Natural materials like the lotus leaf or carapace of thedesert beetle have evolved self-cleaning and water-harvesting surfaces that repel or direct water move-ment in rolling drops. Sandia developed a simple,biomimetic-coating process that allows immediateformation of such “superhydrophobic” coatings onarbitrary surfaces. Water is not merely repelled; itliterally jumps or rolls off. Unlike previous work,Sandia’s process provides perfect transparency andrequires no surface treatment. It can preventcorrosion, protect electronics and antiquities,avoid fogging or icing, and provide a new approachto water collection. (1000, 1800, 8600) ST&E

A use-control component housing afterfabrication of the carbon-fiber compositeshell (left) and after near-net-shape form-ing of the internal features (right) using anew process developed by Center 2400and Honeywell FM&T.

Using Sandia’s new Z facility, shockless compressiondata were obtained on tantalum to four megabar pres-sures, completing a high-level milestone with Los AlamosNational Laboratory for NNSA’s Science Campaign. Thisaccomplishment required precise current pulse shaping, anew target geometry to obtain higher pressures and moreaccurate measurements, shielding of optical diagnosticsin Z’s harsh environment, and careful characterization ofthe time-dependent current loss. The federal programmanager said the data “are a significant advance over anyprevious data available within the complex.” (1600)NW, ST&E

Wire-array implosions on Z produce an approxi-mately five nanosecond X-ray burst with approxi-mately 200 trillion watt peak power. A three-dimensional computational model of Z-pinchimplosions was developed using the radiationmagneto hydrodynamics code ALEGRA. It isproviding critical insights on scaling of wire-arraysources to larger currents for fusion and weaponphysics applications. Validation on the massivelyparallel Red Storm computer proved that themodel produces a broad range of measurementswhen azimuthal asymmetries are included andpredicts X-ray power within measurementuncertainties. (1600, 1400) NW, ST&E

In its first year of operations the refurbished Z facilityreestablished experimental platforms, made key improve-ments to specific components, fielded new diagnostics,and conducted mission experiments for NNSA in severalprogram areas. The new Z has better shot-to-shot repro-

ducibility, more precise current shaping (pulse length canbe varied by a factor of three), and higher peak currents.The new diagnostics significantly enhance measurementsof the accelerator performance and the physics of thehigh-energy-density plasmas. (1600) NW, ST&E

Engineering Sciences Center 1500 provided an indepen-dent peer review of the structural analysis supporting theNational Transportation Safety Board’s investigation of theMinneapolis bridge collapse. On Aug. 1, 2007, the I-35Wbridge across the Mississippi River collapsed suddenly,resulting in 13 deaths and 145 injuries. In a briefing tothe NTSB chairman prior to public hearings on the investi-gation findings, the Sandia team substantiated theprobable cause of failure as a design flaw rather thancorrosion. (1500) NW

Providing support to Sandia’s Work for Others/OtherFederal Agency (WFO/OFA) customers, WFO/CRADAAgreements Dept. 10012 processed 1,145 WFO/OFAagreements in FY08, a 24 percent increase from FY07,and 786 WFO/OFA proposals, an 8 percent increase.The total dollar value of agreements processed increasedby 21 percent. (10000)


The National Institute for Nano-Engineering (NINE) is a Sandia/university/industry collaborationformed to help develop the nextgeneration of nano-engineeringinnovation leaders for the nation.Research opportunities for studentsare enabled by Sandia’s capabilitiestogether with those of 12 universityand six industry partners. This yearNINE carried out 15 technical pro-jects, student programs, and atechnical workshop and workedwith partners to form NINECO,the consortium’s administrativearm. NINE is a prototype DiscoveryScience and Innovation Instituteas envisioned in the AmericaCompetes Act of 2007.(1800, 1030) ST&E

NINE students and mentors(Photo by Randy Montoya)

Two programs that leverage Sandia technologies to createjobs reached major milestones. The EntrepreneurialSeparation to Transfer Technology Program, now inits 15th year, has created 3,100 jobs, started up PermaWorks (www.permaworks.com), and helped expandeSolar (www.esolar.com).

The Sandia Science & Technology Park celebrated its10th anniversary with a series of events that recognizedthe park’s 28 tenants employing 2,100 people. The parkalso was honored by the Greater Albuquerque Chamberof Commerce with its Small Business Advocate of theYear Award. (1030) ST&E

Partnerships & alliances

The eSolar power plant’s small mirrors track the sunwith high precision and reflect sunlight to tower-mounted receivers.

New sign at the Sandia Science & Technology Park

Under the Lockheed Martin cooperative research anddevelopment agreement, Sandia developed a newself-assembled thin film coating technology thatwill generate economic, logistical, and environmen-tal benefits for electronics and high-performanceoptical devices by assembling nanoparticles intoengineered optical and electrical composite films atambient conditions. The ability to repair coatings inthe field reduces needs for spare parts and downtime.This application method is ideally suited for thermalmanagement of aerostats and high-altitude airshipsand components such as adaptive micromirrors,which are extremely difficult to coat using conven-tional thin films. (1800, 300) ITS SMG

Nanoparticle thin film on 2 in. by 2 in. siliconwafer (top) and thin films on acrylic plates(middle and bottom)


IT, networks,& facilities

Bldg. 807 demolitionThe Decontamination andDemolition Program completedthe most ambitious year in its15-year history, removing ordemolishing more than 150,000gross square feet of space. Thisincluded the removal of Bldg.807, the end of a five-year effortto demolish the Bldg. 805/806/807 complex, and Bldg. 893,torn down as part of theMicrosystems and EngineeringSciences Applications project.Removing these substandardfacilities reduces annualmaintenance costs by $2.7million and frees valuable landfor new development to meetSandia’s current and futuremission needs.(4800) IES

Sandia and Qwest Communications have teamed toprovide reliable high-speed network connectivity tothe California site. The system is capable of providingconcurrent wide-area access to multiple governmentagencies and Internet service providers. The initial appli-cations include a new California-New Mexico classifiedintersite link and a 10 gigabit per second network thatsupports site Advanced Simulation & Computing (ASC)applications. (8900) IES

The Sandia Wireless Handheld Communications Teamand California-site Security Operations completed a proofof concept using the California badge swipe system,enabled with Diamond 2 software, to disable selectedBlackBerry device functions. The Sandia default securitypolicy changes to a PDA-mode policy upon entering thelimited area and the PDA-mode security policy returns tonormal during an outbound badge swipe. The proof ofconcept was successful and security policy changesoccurred within a minute of using the badge swipe system.(8900, 8500) IES

FY08 was an exceptional year for Sandia’s EnergyManagement Program. A collaborative effort among Facili-ties and line organizations resulted in improved employeeawareness and construction projects that reduced thenatural gas and electricity use per gross square foot for officeand light lab buildings by 8.9 percent, which saved $1million; lowered greenhouse gas emissions by 10.46 percent;and reduced water use by 52 million gallons. The programcosponsored a site-wide Lights Out campaign, EnergyConservation Month events, Earth Day events, and a highlysuccessful Earth, Wind, and Sun event. (04100, 04800) IES

The ailing 16-year-old New Mexico-to-California intersitenetwork was in need of a rapid reengineering due to relia-bility and cost concerns. The reengineering team developedand deployed the next-generation intersite network.Typical sustained file movement performance improved bymore than 40 times, and reliability improved significantlyas well. The new path utilizes Sandia’s existing EngineeringSciences NETwork (ESNET), saving more than $100,000annually from the previous system. (9300, 8900)

The $518 million Microsystems and EngineeringSciences Applications (MESA) project was completedin August 2008, three years ahead of schedule and $48million under budget. The successful completion metan NNSA Defense Programs “Getting the Job Done”goal and represents the largest federal investment inmicrosystem technologies. In FY08 the MESA team wasrecognized with several awards, including the Secretaryof Energy’s Achievement Honor Award, the NNSADefense Programs Award of Excellence, a DOE Environ-mental Management “Best in Class” Award, and a Lock-heed Martin NOVA Award. (8400, 1500, 1700, 2400,2600, 4100, 4200, 4800, 5300, 10200, 10600) NW

ES&H & security

In February 2008 a Nuclear Assurance Corp. cask is loaded atSandia’s Tech Area 5 with a Sodium Reactor Fuel Debris experi-ment bound for treatment at the Idaho National Laboratory, partof special nuclear material de-inventory efforts.

Special nuclear material de-inventory efforts were sub-stantial in 2008. Sandia was the first DOE site to move allsecurity-sensitive material off-site, and it did so in signifi-cantly less time than the timeframe set by DOE. The firstphase of the de-inventory project was completed inFebruary 2008. This allowed Sandia to aggressively removeremaining items and close the Nuclear Material StorageFacility by the end of September 2008. (1300, 10200, 4200,4300, 2900) NW

Lead-containing ceramics are used in ferroelectric weaponpower supplies and in commercial applications. The leadgreatly increases Sandia’s costs to prevent worker exposureand for waste disposal. Lead-free alternatives previouslyhave not achieved the required performance. A new pro-duction-scalable process has been developed to manufac-ture ceramics with highly oriented microstructures thatdramatically enhance the electrical properties of somelead-free compositions, making them a viable alternativefor selected applications. This reduces risk to workers andthe environment while affording substantial cost savings.(2400, 1800, 1100) NW

The Livermore Chamber of Commerce selected Sandia/California as the recipient of its inaugural EnvironmentalSpirit Award. The award recognizes Sandia’s environmen-tal programs and ongoing commitment to protecting theenvironment, wildlife, and numerous species on the 400-acre site. Gary Shamber, manager of the site’s EnvironmentalManagement Department, accepted the award during thechamber’s annual community awards gala on Feb. 2, 2008.In his acceptance speech, Gary emphasized the growingimportance of environmental stewardship by individuals,companies, and communities. (8500) IES

The success of Phase I of the special nuclear materialde-inventory and the resulting change in security postureallowed Sandia to redeploy equipment, materials, andnonpermanent upgrades to several protective force,physical security, and technical security organizationsthroughout the DOE complex. Redeployed protectiveforce equipment included weapons, breaching equip-ment, night vision equipment and scopes, armored vehi-cles, and ammunition. Physical and technical securityequipment included an X-ray machine, metal detectors,camera towers, and microwave sensors, among otheritems. (4200) NW

On May 12, 2008, the Oracle Explosive Inventory Sys-tem (EIS) was released to production. The Oracle EISreplaces a legacy system that was outdated in technologyand process requirements. The Oracle EIS simplified andautomated 21 processes and provides multiple data analy-sis tools and reports. The successful completion of thedevelopment project met an Office of Inspector General(OIG) finding and resulted from collaboration among SafetyEngineering Dept. 4122, Oracle E-Business Suite SystemDept. 9542, and the Sandia Explosive Safety Committee.(4100, 9500) IES

Among the internal independent audits performed bySandia, two were particularly noteworthy for helpingimprove the safety of Sandians, contractors, and visitors.The pedestrian and traffic safety audit led to a decision toplan a renovation of the Bldg. 825 parking lot to improvedrainage and walking safety for everyone using the lot toreduce slips, trips, and falls. The Saturn and HERMES auditled to the improvement of lighting in two large particleaccelerators for the protection of workers at the facility.(12800, 1300, 6060, 4800) NW, ER&N

New highly oriented lead-free ceramics offer substantiallyimproved ferroelectric properties with the potential to replacelead-containing ceramics in some applications.

Special nuclear material de-inventory activities and the resultingchange in security posture allowed Sandia to redeploy protectiveforce, physical security, and technical security equipment aroundthe complex. (Photo by Randy Montoya)


Human resourcesHealth, Benefits, and Employee Services (HBE) deployslong-term containment strategies to control escalatinghealth care costs. With careful management of off-siteand on-site health care services and employee education,HBE (http://hbe.sandia.gov) encourages a healthy work-place culture where individual responsibility, informedconsumerism, prevention, and disease management resultin better health outcomes and savings. This year, HBEbrought on new prescription and vision care vendors,implemented electronic medical records and an onlineconsumer-to-provider portal, assessed organizationalhealth, and educated employees within work groups. HBEalso implemented a drug testing program for DOE. (3300)

The new staff augmentation contracts awarded inJune 2008 use more than 1,300 contractor personneland represent the largest contract workforce of anyDOE contractor. Deploying the new contractsinvolved the largest transition of a contract workforcein Sandia history. Several industry leaders in the federalcontractor sector are benchmarking Sandia’s approachas a best-in-class model, including the Jet PropulsionLaboratory, Lawrence Livermore National Laboratory,Los Alamos National Laboratory, Honeywell FM&T,Pacific Northwest National Laboratory, and Pantex.(10200, 3500, 9500, 4200) IES

Supply chain

Governance, leadership, & managementSandia’s Integrated LaboratoryManagement System (ILMS)has undergone continuousimprovement. FY08 improve-ments include formalized man-agement reviews; establishmentof the first integrated set ofLabs-wide performancemeasures; implementationof updated assure, assess, andimprove processes; deploymentof new portal technology andcorporate application upgrades;standardized Executive Office,Laboratory Leadership Team,Strategic Management Group,Strategic Management Unit,Division, and Policy Area pagesand content; and a three-year,resource-loaded developmentplan for ILMS. (9700, 6300,9500, 9600)

The Strategic Planning Department of the InstitutionalDevelopment Center engaged laboratory leadership ina new approach to strategic planning — assumption-based planning. This approach articulates key assump-tions about the external and internal environments,identifies load-bearing assumptions and uncertainties,and clarifies key shaping and hedging actions. Thismodified approach to strategic planning is intended toresult in a more robust and integrated set of strategicactions as Sandia moves into the future. (12100)

NNSA Headquarters recognized Sandia in March 2008with the first annual Administration Award forExcellence in Internal Controls. The award acknowl-edges Sandia’s exceptional internal control activities asdemonstrated within the Labs’ implementation ofOMB Circular A-123 and contractor assurance. Theseactivities help ensure that Sandia is a sound steward oftaxpayer dollars. The award was based on a complex-wide examination of contractor management assurancesystems. Sandia was the only recipient in FY08. ChiefFinancial Officer & Business Operations VP Matt O’Brienaccepted the award on behalf of Sandia.(12800, 10500) IES

A Sandia team played a leadership role in and providedintegrated support for the NNSA Nuclear WeaponsComplex Supplemental Programmatic Environmen-tal Impact Statement (SPEIS) process. In the NNSASPEIS record of decision: 1) Sandia retained the coordi-nation and oversight of flight test operations atTonopah Test Range; 2) major environmental testfacilities are consolidated to Sandia/New Mexico; 3)the Sandia/California site continues its weapons non-nuclear design and support functions; and 4) highexplosives R&D support functions, including use ofenergetic materials for environmental testing, continueat Sandia. (200, 2700, 2900, 1300, 1500, 8500) NW

In the triennial DOE Counterintelligence Inspection,Sandia received an “Excellent,” the highest ratingpossible. The final inspection notes that “SNL DirectorDr. Thomas Hunter and his executive managementteam are exceptionally supportive” of Sandia counter-intelligence. In a congratulatory note, the NNSAadministrator said, “The results of this inspection werequite impressive . . . in fact, I understand that this wasone of the best overall results across the Department.”(300)

Workers install components during refurbishment of Sandia’sZ machine. (Photo by Randy Montoya)

Community involvementIn a year of great commu-nity need, Sandia employeeschose to make a difference.For the first time since 1994,Sandia’s Employee CaringProgram (ECP) participationrate reached 76 percent.Sandia’s campaign raisedmore than $3.7 million.Retirees donated more than$450,000. Employee dona-tions increased by morethan $200,000 from the pre-vious year. New-employeeparticipation rose by 3.9 per-cent. Sandia is the largestcontributor to the UnitedWay of Central New Mexico.

More than 850 Sandians areactive volunteers who gavemore than 114,000 volunteerhours to their communitiesin 2008.

Albuquerque school childrenreceive shoes from Sandiavolunteers. Sandia’s 50-year-old Shoes for Kids program isone of Sandia’s many com-munity giving and outreachprograms.

(Photo by Randy Montoya)

Peter Roth (2546) prepares to blow up a batteryas part of the DOE-funded FreedomCAR program.Sandia’s battery abuse research program isrecognized internationally for electric vehicleapplications. See page 5.

(Photo by Randy Montoya)

Documents

Lab Accomplish 2009