Lockheed Martin Santa Cruz Facility Ordnance System Design, Manufacture and Test

Lockheed Martin Space Systems Company Santa Cruz Facility 16020 Empire Grade Road Santa Cruz, CA 95060
K8149

831-425-6262 scf.fbm@lmco.com www.lockheedmartin.com

2008 Lockheed Martin Corporation

Ensuring Reliability for Key National Programs

In the development and performance of rocket and missile programs, there is little room for error. The ordnance components built and tested by Lockheed Martins Santa Cruz, Calif., Facility must work the first time, every time. Since 1957, the Santa Cruz Facility has delivered vital support to important U.S. government programs such as Peacekeeper and the space shuttle, and today supports programs such as the U.S. Navys Trident II D5 Fleet Ballistic Missile (FBM) and the U.S. Missile Defense Agencys Terminal High Altitude Area Defense (THAAD) system. In its role as FBM prime contractor, Lockheed Martin uses the facility as the primary site for manufacture and environmental, safety and functional testing of FBM ordnance devices and materials. Carried by strategic submarines, the D5 missile uses these devices during flight to ignite rocket motors and gas generators and separate missile stages and components. From a remote corner of Californias San Francisco Bay Area, the facility has supported the D5 and five earlier generations of FBM while maintaining an outstanding safety and performance record, thanks to a skilled government-industry partnership. Since 1989, a string of more than 120 successful D5 missile test launches by the U.S. and United Kingdom navies has demonstrated the contributions of the Santa Cruz Facility to the reliability of the FBM program.

Conducted at the Santa Cruz Facility in late 2004, a Short Hot Launch test for the THAAD system helped demonstrate the programs readiness for flight testing.

On the cover:
Lockheed Martin staff at the Santa Cruz, Calif., Facility conducts a full system test of the Post Boost Control System. This system, which consists of two pairs of solid-propellant gas generators and four integrated valve assemblies, maneuvers the U.S. Navys Trident II D5 Fleet Ballistic Missile following the separation of all three boost-motor stages.

First deployed in 1990, the D5 missile is the principal armament of 14 Trident Ohio-class submarines and four United Kingdom Vanguard-class submarines. The three-stage, solid-propellant, inertial-guided D5 can travel a nominal range of 4,000 nautical miles and carries independently targeted reentry vehicles.

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The Santa Cruz Facility Team

Safe and Reliable Space and Missile Systems
Ordnance devices and materials, including propellants, are used on launch vehicles and ballistic missiles to separate stages or create thrust. Building and testing these devices safely requires an exceptionally skilled workforce with an unwavering focus on than 80 ordnance specialists includes electrical and mechanical engineers, physicists, chemists, energetics experts and technicians. These specialists design, develop, manufacture and test a range of ordnance devices. In addition to missile stage separators and rocket motor igniters, the team tests devices for the Navys D5 missile test launch program. These include flight termination systems, which can destroy missiles in flight to ensure range safety. State-of-the-art techniques and equipment include environmental generators, high- and low-speed photo instrumentation, radiographic inspection, leak detection, metrology, and chemical and physical properties determination.

Fleet Ballistic Missile Program

One of the key programs supported by the Santa Cruz Facility is the Navys FBM program. At the facility, Lockheed Martin performs FBM work under the direction of U.S. Navy personnel from the Program Management Office, Strategic Systems Programs Flight Systems, which is based about35 miles away in

Sunnyvale, Calif. The facility reports to the companys FBM program office, also located in Sunnyvale, and has access to scientists and engineers at Lockheed Martins Advanced Technology Center in Palo Alto, Calif. Altogether, more than 2,600 Lockheed Martin employees in California, Washington, Georgia, Florida, Utah, Virginia, and the United Kingdom serve every aspect of the FBM program, from design, development and production to testing and operation.

At all sites, the NavyLockheed Martin team conducts business according to a set of shared values, principles and tools proven over five decades. The FBM approach includes (1) common priorities and goals, (2) open and trusted communicationssurfacing problems early and solving them together, (3) a focus on time-tested solutions, (4) disciplined technical and business management controls, and (5) commitment to maintaining a skilled FBM workforce.

Electro-Optical Sensing
In addition to ordnance work, the Santa Cruz Facility serves as a field test site for active and passive electro-optical sensing. In this role, the team supports work on directed energy/laser research, missile-defense target sensing and discrimination, NASA spectroscopy missions, and space-based communications, intelligence, surveillance, reconnaissance, and situational awareness.

meeting performance requirements as well as environmental, safety and health regulations. The Santa Cruz Facility teams extensive experience in ordnance and propulsion testing ranges from the stresses of shock and vibration to a variety of thermal environments. The team of more

Strategic Systems Programs Flight Systems

The Program Management Office, Strategic Systems Programs (PMOSSP) Flight Systems, is the Navy command that directs and provides technical oversight to Lockheed Martin and subcontractors to ensure successful manufacture and test of the Trident II D5 missile system. PMOSSP Flight Systems also is responsible for the missile guidance system and for management of other subsystem prime contractors. Responsibilities of this command include engineering, design and configuration management, guidance, support equipment, documentation, logistics and program planning. For more than 50 years, PMOSSP and Lockheed Martin have conducted a highly successful partnership to develop increasingly capable and reliable submarine-launched ballistic missiles. Current objectives of this partnership include the D5 Life Extension program, which will ensure Trident D5 missiles will be available for the lifetime of the Trident submarine fleet, until 2042, and converting selected Trident submarines to platforms for launching conventional Tomahawk cruise missiles. PMOSSP Flight Systems reports to the Strategic Systems Program (SSP), headquartered in Washington, D.C. In 2001 Flight Systems received the first Raborn award, signifying overall command excellence. It received Navy Unit Commendations in 1979 and 1990, respectively, for successful development of the Trident I C4 missile and the Trident II D5 missile.

A Line-of-Sight Stabilization test demonstrates that the seeker for the Terminal High Altitude Area Defense System can stabilize on a fixed point while the missiles divert and attitude control thrusters are firing.

Achieving Ignition, Separation and Destruct

Ordnance Events for the Trident II D5 Missile
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Ignition of Thrust Vector Control (TVC) subsystem, 1st stage Rocket motor ignition, 1st stage Ignition of TVC subsystem, 2nd stage 1st stage separation Rocket motor ignition, 2nd stage Separation and jettison of nose fairing Ignition of TVC subsystem, 3rd stage 2nd stage separation and 3rd stage rocket motor ignition Ignition of Post Boost Control System (PBCS) 3rd stage separation and eject motor ignition Payload (reentry body) release Destruct events (for test missiles only): 1st stage 2nd stage 3rd stage PBCS stage LOS Harness Separation Charge Explosive Separation Nuts Thrusters LOS Harness HVD TBI FLSC FLSC HVD TBI SLSC PBCS Destruct LOS Harness TBI HVD Aerospike Inertial Initiator TBI LOS Harness

SLSC

SLSC HVD LOS Harness FLSC TBI HVD

Facility Capabilities for Defense Systems

At the Santa Cruz Facility, Lockheed Martin offers a range of design, manufacturing, test and support services for defense systems and components. Design Ordnance Systems Separation Systems Flight Termination Systems Energy Transfer Systems Manufacture Linear Ordnance System (LOS) Harnesses Through-Bulkhead Initiators (TBI) Post Boost Control System (PBCS) Destruct Assemblies Igniters Detonating Cords Transfer Lines Crossover Blocks Union Blocks Testing Erosional exposure to erosive effects of propellant combustion Vulnerability exposure to structural loads and hydrodynamics Environmental exposure to extreme temperature and humidity conditions Cryogenic exposure to cold temperatures Shock and Vibration exposure to the rigors of launch and other stresses Over-the-Air Test Range long- and short-range transmit and receive Support services Planning preparing test plans, schedules, specifications and related test documentation Design designing test setups Procurement procuring test materials as needed Machining fabricating special test equipment as needed Instrumentation equipping test stands so that useful data can be collected High-Speed Photography capturing rapid events for later analysis Chemical Analysis determining chemical changes that occur during testing Measurement/Metrology ensuring accurate and precise measurement of test results Failure Diagnosis analyzing test anomalies

LOS Harness HVD LOS Harness FLSC

Essential to performance of the three-stage Trident II D5 missile is a subsystem of small ordnance devices that (1) ignite rocket motors and gas generators, (2) separate stages and (3) disable missiles in the event of a flight test malfunction. The conventional explosive charges used for missile destruct, the Post Boost Control System (PBCS) destruct assemblies and Flexible Linear Shaped Charges (FLSC), are armed only in missiles used for test flights. A typical ordnance sequence begins with activation of High-Voltage Detonators (HDV). The energy from these devices travels through

Ordnance Device Color Key Ignition / Separation / Destruct

Linear Ordnance System (LOS) harnesses to specific locations throughout the missile. Throughbulkhead initiators transmit this energy to ignite rocket motors and gas generators. The gas generators activate the thrust vector control systems that tilt rocket motor nozzles as needed during flight. The LOS also transmits the energy to ignite Separation Linear Shaped Charges (SLSC) for the separation of stages.

A Commitment to Community
Lockheed Martin is committed to being a good neighbor. In the coastal mountain setting of the Santa Cruz Facility, we are attentive to the need for rigorous safety precautions and for stringent measures to preserve the surrounding mountain environment. In the history of the facility, no major chemical spills or improper release of materials have ever occurred, and our compliance with environmental, safety and health regulations is validated annually by county, state, federal and corporate auditors. We have a manufacturing license from the U.S. Department of Alcohol, Tobacco and Firearms, and we are compliant with the U.S. Navys ordnance safety requirements. Hazardous materials stored at the facility are transported according to strict U.S. Department of Transportation guidelines. When these materials are no longer needed, we use state-approved hazardous waste transporters to transfer them to Environmental Protection Agencyapproved storage, treatment and disposal sites. As an additional safety measure, we maintain a trained emergency response team on site that coordinates with the local Bonny Doon Fire Team, and we have a longstanding relationship with the California Department of Forestry. In addition to looking out for our mountain environment, we support outreach and cultural activities in nearby communities. Our employees, many of whom live near the facility, volunteer in local schools and contribute their time and resources to non-profit organizations. Lockheed Martin also contributes to local community resources including festivals, museums and environmental groups.

An Unwavering Focus on Safety

At the Santa Cruz Facility, safety is at the forefront of every process, every decision. Occupying 4,000 acres, the facility has been carefully designed for manufacturing and test safety, including special equipment and protocols and adequate distances for the safe handling of ordnance. Propellant materials are stored in small quantities and handled according to strict step-by-step procedures. Typical maximum working quantities of propellant are 10 grams or less; most test subjects contain just milligrams of propellant. Lockheed Martin takes great pride in our safety record at the Santa Cruz Facility: 30,000plus test sequences conducted during more than 2 million hours of propellant and ordnance testing without loss of life or catastrophic test incident in 50 years of operation.

Proven Partnership
For nearly five decades, the United States strategic deterrent capability has depended on the quality of work conducted at the Santa Cruz Facility and other Lockheed Martin facilities throughout the United States. Our continuing goal: partner with the U.S. and U.K. navies to ensure the safety, readiness and reliability of the Fleet Ballistic Missile program.