Lockheed Martin Space Systems Company

Santa Cruz Facility 16020 Empire Grade Road Santa Cruz, CA 95060

831-425-6262

scf.fbm@lmco.com www.lockheedmartin.com

Lockheed Martin Santa Cruz FacilityOrdnance System Design, Manufacture and Test

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© 2008 Lockheed Martin Corporation

In the development and performance of rocket and mis-

sile programs,there is littleroom for error.The ordnancecomponentsbuilt and testedby LockheedMartin’s Santa

Cruz, Calif., Facility must workthe first time, every time.

Since 1957, the Santa CruzFacility has delivered vital supportto important U.S. governmentprograms such as Peacekeeperand the space shuttle, and todaysupports programs such as theU.S. Navy’s Trident II D5 FleetBallistic Missile (FBM) and the

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First deployed in 1990, the D5 missile is the principal armament of 14 Trident Ohio-class sub-marines and four United Kingdom Vanguard-classsubmarines. The three-stage, solid-propellant,inertial-guided D5 can travel a nominal range of4,000 nautical miles and carries independentlytargeted reentry vehicles.

U.S. Missile Defense Agency’sTerminal High Altitude AreaDefense (THAAD) system.

In its role as FBM primecontractor, Lockheed Martinuses the facility as the primarysite for manufacture and envi-ronmental, safety and func-tional testing of FBM ordnancedevices and materials. Carriedby strategic submarines, the D5missile uses these devices duringflight to ignite rocket motorsand gas generators and separatemissile stages and components.

From a remote corner ofCalifornia’s San Francisco BayArea, the facility has supportedthe D5 and five earlier genera-tions of FBM while maintain-ing an outstanding safety andperformance record, thanks to a skilled government-industrypartnership. Since 1989, a stringof more than 120 successful D5missile test launches by the U.S.and United Kingdom navies hasdemonstrated the contributionsof the Santa Cruz Facility to thereliability of the FBM program.

On the cover:Lockheed Martin staff at the Santa Cruz, Calif., Facility conductsa full system test of the Post Boost Control System. This system,which consists of two pairs of solid-propellant gas generators andfour integrated valve assemblies, maneuvers the U.S. Navy’s TridentII D5 Fleet Ballistic Missile following the separation of all threeboost-motor stages.

Ensuring Reliability for KeyNational Programs

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Conducted at the Santa Cruz Facility in late 2004, a “ShortHot Launch” test forthe THAAD systemhelped demonstrate the program’s readi-ness for flight testing.

than 80 ordnance specialistsincludes electrical and mechanicalengineers, physicists, chemists,energetics experts and technicians.

These specialists design,develop, manufacture and test arange of ordnance devices. Inaddition to missile stage separa-tors and rocket motor igniters,the team tests devices for theNavy’s D5 missile test launchprogram. These include flight termination systems, which can destroy missiles in flight to ensure range safety.

State-of-the-art techniquesand equipment include environmental generators, high- and low-speed photoinstrumentation, radio-graphic inspection, leak detection, metrology, and chemical and physical properties determination.

The Santa Cruz Facility Team

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Safe and Reliable Spaceand Missile Systems

Ordnance devices and materi-als, including propellants, areused on launch vehicles and bal-listic missiles to separate stages orcreate thrust. Building and test-ing these devices safely requiresan exceptionally skilled workforcewith an unwavering focus on

meeting performance require-ments as well as environmental,safety and health regulations.

The Santa Cruz Facilityteam’s extensive experience inordnance and propulsion testingranges from the stresses of shockand vibration to a variety ofthermal environments. The team of more

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Fleet Ballistic MissileProgram

One of the key programs sup-ported by the Santa Cruz Facilityis the Navy’s FBM program. Atthe facility, Lockheed Martin performs FBM work under thedirection of U.S. Navy personnelfrom the Program ManagementOffice, Strategic SystemsPrograms Flight Systems, which isbased about35 miles away in

Sunnyvale, Calif. The facilityreports to the company’s FBMprogram office, also located inSunnyvale, and has access to sci-entists and engineers at LockheedMartin’s Advanced TechnologyCenter in Palo Alto, Calif.

Altogether, more than 2,600Lockheed Martin employees inCalifornia, Washington, Georgia,Florida, Utah, Virginia, and theUnited Kingdom serve everyaspect of the FBM program, fromdesign, development and produc-tion to testing and operation.

At all sites, the Navy–LockheedMartin team conducts businessaccording to a set of shared values,principles and tools proven overfive decades. The FBM approachincludes (1) common priorities andgoals, (2) open and trusted commu-nications—surfacing problemsearly and solving them together, (3)a focus on time-tested solutions, (4)disciplined technical and businessmanagement controls, and (5) com-mitment to maintaining a skilledFBM workforce.

Electro-Optical Sensing

In addition to ordnance work, the Santa Cruz Facility serves as afield test site for active and passiveelectro-optical sensing. In this role,the team supports work on directedenergy/laser research, missile-defensetarget sensing and discrimination,NASA spectroscopy missions, andspace-based communications, intelli-gence, surveillance, reconnaissance, and situational awareness.

The Program Management Office, StrategicSystems Programs (PMOSSP) Flight Systems, is theNavy command that directs and provides technicaloversight to Lockheed Martin and subcontractors toensure successful manufacture and test of the TridentII D5 missile system. PMOSSP Flight Systems also isresponsible for the missile guidance system and formanagement of other subsystem prime contractors.

Responsibilities of this command include engi-neering, design and configuration management, guid-ance, support equipment, documentation, logisticsand program planning. For more than 50 years,PMOSSP and Lockheed Martin have conducted ahighly successful partnership to develop increasinglycapable and reliable submarine-launched ballistic mis-siles. Current objectives of this partnership include theD5 Life Extension program, which will ensure TridentD5 missiles will be available for the lifetime of the

Strategic Systems Programs Flight SystemsTrident submarine fleet, until 2042, and convertingselected Trident submarines to platforms for launchingconventional Tomahawk cruise missiles.

PMOSSP Flight Systems reports to the StrategicSystems Program (SSP), headquartered in Washington,D.C. In 2001 Flight Systems received the first Rabornaward, signifying overall command excellence. It received Navy UnitCommendations in1979 and 1990,respectively, forsuccessfuldevelopmentof the TridentI C4 missileand the TridentII D5 missile.

A Line-of-SightStabilization test demon-strates that the seeker forthe Terminal High AltitudeArea Defense System canstabilize on a fixed pointwhile the missile’s divertand attitude controlthrusters are firing.

Achieving Ignition, Separation and DestructOrdnance Events for the Trident II D5 Missile

1. Ignition of Thrust Vector Control (TVC) subsystem, 1st stage2. Rocket motor ignition, 1st stage3. Ignition of TVC subsystem, 2nd stage4. 1st stage separation5. Rocket motor ignition, 2nd stage6. Separation and jettison of nose fairing7. Ignition of TVC subsystem, 3rd stage8. 2nd stage separation and 3rd stage rocket motor ignition9. Ignition of Post Boost Control System (PBCS)10. 3rd stage separation and eject motor ignition11. Payload (reentry body) release

Destruct events (for test missiles only):12. 1st stage 13. 2nd stage14. 3rd stage15. PBCS stage

Essential to performance of the three-stageTrident II D5 missile is a subsystem of small ord-nance devices that (1) ignite rocket motors and gasgenerators, (2) separate stages and (3) disable mis-siles in the event of a flight test malfunction. Theconventional explosive charges used for missiledestruct, the Post Boost Control System (PBCS)destruct assemblies and Flexible Linear ShapedCharges (FLSC), are armed only in missiles usedfor test flights.

A typical ordnance sequence begins with activation of High-Voltage Detonators (HDV). The energy from these devices travels through

Linear Ordnance System (LOS) harnesses to specific locations throughout the missile. Through-bulkhead initiators transmit this energy to igniterocket motors and gas generators. The gas genera-tors activate the thrust vector control systems thattilt rocket motor nozzles as needed during flight.The LOS also transmits the energy to igniteSeparation Linear Shaped Charges (SLSC) for the separation of stages.

Separation Charge

Ordnance Device Color KeyIgnition / Separation / Destruct

Aerospike Inertial Initiator

HVDTBISLSCPBCS Destruct

LOS Harness

LOS HarnessHVD

LOS Harness

LOS Harness

HVDLOS HarnessFLSC

SLSCHVD

LOS Harness

SLSC

Explosive Separation NutsThrusters TBI

LOS Harness

TBIHVD

TBIFLSC

FLSCTBIHVD

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

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

Facility Capabilities for Defense Systems

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A Commitment to CommunityLockheed Martin is committed to being a good

neighbor. In the coastal mountain setting of theSanta Cruz Facility, we are attentive to the need for

rigoroussafety pre-cautions andfor stringentmeasures topreserve thesurroundingmountainenvironment.In the his-tory of thefacility, nomajor chemi-

cal spills or improper release of materials have everoccurred, and our compliance with environmental,safety and health regulations is validated annuallyby county, state, federal and corporate auditors.

We have a manufacturing license from the U.S.Department of Alcohol, Tobacco and Firearms, andwe are compliant with the U.S. Navy’s ordnancesafety require-ments.

Hazardousmaterials stored at the facility are transportedaccording to strictU.S. Departmentof Transportationguidelines. When these materials are no longerneeded, we use state-approved hazardous wastetransporters to transfer them to EnvironmentalProtection Agency–approved storage, treatment anddisposal sites.

As an additional safety measure, we maintain atrained emergency response team on site that coor-dinates with the local Bonny Doon Fire Team, andwe have a longstanding relationship with theCalifornia Department of Forestry.

In addition to looking out for our mountainenvironment, we support outreach and culturalactivities in nearby communities. Our employees,many of whom live near the facility, volunteer inlocal schools and contribute their time and resourcesto non-profit organizations. Lockheed Martin alsocontributes to local community resources includingfestivals, museums and environmental groups.

An Unwavering Focus on SafetyAt 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 testsafety, including special equipment and protocolsand adequate distances for the safe handling of ordnance.

Propellant materials are stored in small quanti-ties and handled according to strict step-by-stepprocedures. Typical maximum working quantitiesof propellant are 10 grams or less; most test subjects contain just milligrams of propellant.

Lockheed Martin takes great pride in oursafety record at the Santa Cruz Facility: 30,000-plus 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.

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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.