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US Forgets How To Make Trident Missiles

Posted by CmdrTaco on Mon Mar 09, 2009 09:46 AM
from the i-forget-how-to-spell-feal dept.
Hugh Pickens writes "The US and the UK are trying to refurbish the aging W76 warheads that tip Trident missiles to prolong their life and ensure they are safe and reliable but plans have been put on hold because US scientists have forgotten how to manufacture a mysterious but very hazardous component of the warhead codenamed Fogbank. 'NNSA had lost knowledge of how to manufacture the material because it had kept few records of the process when the material was made in the 1980s, and almost all staff with expertise on production had retired or left the agency,' says the report by a US congressional committee. Fogbank is thought by some weapons experts to be a foam used between the fission and fusion stages of the thermonuclear bomb on the Trident Missile and US officials say that manufacturing Fogbank requires a solvent cleaning agent which is 'extremely flammable' and 'explosive,' and that the process involves dealing with 'toxic materials' hazardous to workers. 'This is like James Bond destroying his instructions as soon as he has read them,' says John Ainslie, the co-ordinator of the Scottish Campaign for Nuclear Disarmament, adding that 'perhaps the plans for making Fogbank were so secret that no copies were kept.' Thomas D'Agostino, administrator or the US National Nuclear Security Administration, told a congressional committee that the administration was spending 'a lot of money' trying to make 'Fogbank' at Y-12, but 'we're not out of the woods yet.'"
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  • by armer (533337) <glenn,vander,veer&gmail,com> on Monday March 09 2009, @09:48AM (#27121179)
    you can download the instruction from the Pirate Bay...
    • Re:Rumor has it.. (Score:5, Insightful)

      by Daravon (848487) on Monday March 09 2009, @11:02AM (#27122283)

      Didn't you read the article/summary? The torrent is dead, because all the seeds went away.

      On the other hand, we should just ask China. I'm sure they have some copies of the recipe laying around...

    • by Intron (870560) on Monday March 09 2009, @11:09AM (#27122417)

      I thought it was just:

      svn co https://trident.nnsa.gov/svnroot/fogbank [nnsa.gov] --username=guest --password=topsecret

    • Re:Rumor has it.. (Score:5, Insightful)

      by jc42 (318812) on Monday March 09 2009, @11:11AM (#27122453) Homepage Journal

      you can download the instruction from the Pirate Bay...

      Just wait a few weeks; you might be right ...

      My immediate thought was related: The US government probably does have the info hidden away in some obscure department's archives, hidden behind a wall of secrecy and classification. The repair guys just don't have the right clearances, and instead of saying "We can't give you that information", the agency says "We don't have that information".

      It could also be a case of Clarke's third law. The information is stored away somewhere, but the repair crews don't know the name of the archive or who runs it, and the people at the archive haven't heard that anyone's looking for it. And chances are that if you ask for the info using the part's name, they won't be able to find it; you have to tell them the code number (or whatever they call it) for that particular part.

      That is, the information could be hidden by ignorance and incompetence, not by any active efforts to hide or eliminate the information. That happens all the time any large organization, businesses as well as governments.

      Actually, my other thought was "Did they google it?" Chances are that google could tell them the part number(s), and maybe also the torrent name at the Pirate Bay.

  • by fodi (452415) on Monday March 09 2009, @09:51AM (#27121231)

    Just get Gordon Ramsay to taste it. He'll tell you what's in it.

  • Not the only time (Score:5, Interesting)

    by EdZ (755139) on Monday March 09 2009, @09:52AM (#27121245)
    A similar problem exists with the SR-71's engines: some key documentation was destroyed in the interests of secrecy, which has greatly complicated maintenance work on the remaining aircraft.
      • Re:Not the only time (Score:5, Interesting)

        by drinkypoo (153816) <martin.espinoza@gmail.com> on Monday March 09 2009, @10:12AM (#27121519) Homepage Journal

        Who is still flying them? To my knowledge the last SR-71 flight was 10 years ago or so.

        They have two at Beale AFB in Marysville, CA. According to people I know who work on base, one is kept in a constant state of operational readiness. That's expensive, so you wouldn't do this unless you were using the damned thing. You'd never notice a launch, because they're launching aircraft of all sizes out of there night and day with constant training flights and U2 overflight.

      • Re:Not the only time (Score:5, Interesting)

        by je ne sais quoi (987177) on Monday March 09 2009, @10:15AM (#27121559)
        NASA [nasa.gov] was still flying them, as they were, and still are as far as I know, the highest flying and fastest aircraft available. That article I linked to says the last flight was in 1999.

        Incidentally, regarding lost war tech., I had always heard that the U.S. no longer has the ability to cast the shells for the large 16" guns on the iowa class battleships, I have no idea if it's true though.
      • by Rich0 (548339) on Monday March 09 2009, @11:08AM (#27122393) Homepage

        I'm not usually the conspiracy-theory type, but I suspect that the USAF already is flying an SR-71 replacement and this is why they have been retired.

        Spy Satellites and UAVs certainly cover parts of the SR-71 mission profile. However, what about battlefield survailence of a major military adversary? Current UAVs cannot survive in combat. Sure, they can loiter over Basra all day when nobody has anything other than a rifle to shoot at them with. Try to get footage of downtown Tehran with a UAV and you'll just have UAV-parts raining all over the place. Satellites certainly work better, but they're very limited in coverage and have no loiter capability. They're also very vulnerable if somebody is determined enough to actually start shooting them down.

        I'm not saying you couldn't do the job with a UAV with SR-71-like capabilities. That is certainly an option. Perhaps one already exists. However, neither satellites or the currently public UAV options make the SR-71 completely obsolete. Either the US doesn't think it needs ariel recon of hot areas, or it has some other way of doing it that nobody knows about.

  • Disinformation (Score:5, Insightful)

    by Demonantis (1340557) on Monday March 09 2009, @09:57AM (#27121291)
    I think this speaks of a larger problem in how the US government organizes itself. NASA had the same issue with some spaceship components because new people were not trained on how legacy systems were built. This issue is happening through many departments in the US government. The US government's extreme isolationism and disinformation for public forums allows them to be years ahead in technology that could help the general public, but means that the people can't benefit from the technology they fund until it has been independently discovered or rendered a relic by some new technology.
    • NASA had the same issue with some spaceship components because new people were not trained on how legacy systems were built.

      I hope you're not referring to the "we lost the blueprints to the Saturn V" urban legend. Because if you are, you need to be aware that the US has all the plans and the experience it needs to rebuild these craft. What it doesn't have is the heavy industrial base. Material science has moved the US significantly forward from the heavy metal construction and high noise/high latency electronics used in the original SatV. Rebuilding the SatV would be more effort than just designing a new spacecraft.

      If you're just referring to a few components here and there, then I have to argue that these things just happen. Systems age, get out of date, and certain challenges arise in maintenance. For someone like NASA, they're not that difficult to solve. It can take quite a few man hours to understand the part properly and re-machine it (even if original staff are on hand; people tend to forget things over time), but the job still gets done with a minimum amount of fuss.

      This issue is a far more worrisome problem. Due to the need for secrecy (there was a HUGE concern that the USSR would obtain our technology), many of the steps were maintained as secrets in people's heads rather than on paper. That makes it difficult to combat the brain drain that invariably happened both as the engineers and researchers aged and the Cold War wound down.

  • by east coast (590680) on Monday March 09 2009, @09:59AM (#27121333)

    This is why it's important to document your code... or your warheads. Either or.

  • by Cassini2 (956052) on Monday March 09 2009, @10:01AM (#27121347)

    The material in the design specification was essentially unobtanium. It couldn't be manufactured at all. Quietly, the manufacturing engineers developed a solution that almost met all of the design specifications, and this was an excellent compromise. Unfortunately, the design engineers couldn't be convinced to sign off on the design change because of quality procedure 15, and military qualification 7. However, the biggest reason the design engineers wouldn't sign off on the change was because of a supposedly critical but practically useless mandatory project requirement, like the missile must work when fired in -40 degree water from 20 feet under the polar ice shelf.

    The manufacturing engineers decided that the "fire nuclear missile while under ice shelf function", probably wouldn't be used, so the modified material was actually just fine. They shipped the missiles, got paid, and everyone was happy. Until now, when someone tries to "fix" the original "fix".

    This story has happened before and will happen again. Whenever you bump into a design that requires a part that "does not exist", watch out for the possibility that the part never did "exist". It could be that you are reading a "design" document, and not what manufacturing actually built. I've worked in manufacturing, and there are lots of stories about impossible to make designs that somehow got shipped.

    • by Torontoman (829262) on Monday March 09 2009, @10:03AM (#27121375)

      My European grandmother made a cake that could easily withstand the middle stages of a nuclear explosion.

    • by troll8901 (1397145) * <troll8901@gmail.com> on Monday March 09 2009, @10:07AM (#27121423) Journal

      The material in the design specification was essentially unobtanium.

      ... also known as element 404.

    • Often times... (Score:5, Interesting)

      by gillbates (106458) on Monday March 09 2009, @11:00AM (#27122249) Homepage Journal

      That "supposedly critical but practically useless mandatory project requirement" is the result of experience. Inexperienced engineers often make the mistake of assuming that if they can't understand why the requirement exists, it must be arbitrary.

      Perhaps this is apocryphal, but during the Cold War, submarines would routinely get stuck under polar ice floes. Having a missile which would work when fired from underneath the polar ice was probably a very large concern for the system designers. Had the engineers pointed out the impossibility of this requirement, it is possible that military doctrine would have been changed to reflect the limitations of the technology. If you are correct about the difference between requirements, design, and actual manufacture, then the actions of these engineers (or perhaps bureaucrats) put the entire United States at risk of nuclear holocaust. Had the Soviets known this during the Cold War, they might have been more willing to risk a nuclear confrontation.

  • by jpmorgan (517966) on Monday March 09 2009, @10:14AM (#27121543) Homepage

    See, this is what happens when you don't continue to spend money on extremely advanced engineering projects: you lose the technology. Technology isn't just a textbook and some blueprints, it requires the experience and knowledge of scientists and engineers. It's a living thing: shelve it, and it dies.

    It would be nice to think this would serve as an abject lesson to congresscritters, next time they think about cutting funding for something 'we don't need right now.' Although I'm cynical enough not to believe that.

  • by Anonymous Coward on Monday March 09 2009, @10:23AM (#27121667)

    Having worked at this facility in the '80's as an engineer, I can say definitively that this scenario is either misunderstood, or incorrectly reported, or deliberately obfuscated, or a lie, or postulated from sketchy evidence, but it is factually and wholly wrong.

    Every project for every material or product, special or otherwise, was properly documented. These files would not be destroyed. (Note here that I'm assuming the files on "fogbank" were not lost in an accident or by malicious destruction.)

    Now, has the practical and hands-on knowledge of the step-by-step, moment-by-moment synthesis reaction to make this material been lost? Perhaps in the course of 25 years it has. Lots of people have left the plant since then. But all the information, notations and observations necessary to reconstruct the process/project do exist, I assure you.

    • by Registered Coward v2 (447531) on Monday March 09 2009, @10:35AM (#27121865)

      Having worked at this facility in the '80's as an engineer, I can say definitively that this scenario is either misunderstood, or incorrectly reported, or deliberately obfuscated, or a lie, or postulated from sketchy evidence, but it is factually and wholly wrong.

      Every project for every material or product, special or otherwise, was properly documented. These files would not be destroyed. (Note here that I'm assuming the files on "fogbank" were not lost in an accident or by malicious destruction.)

      Now, has the practical and hands-on knowledge of the step-by-step, moment-by-moment synthesis reaction to make this material been lost? Perhaps in the course of 25 years it has. Lots of people have left the plant since then. But all the information, notations and observations necessary to reconstruct the process/project do exist, I assure you.

      Great point. My experience is often when people we say "we lost the instructions..." they really mean:

      1. We've scrapped the production line and its components so we do not have the physical capability to build x anymore, or

      2. We have the instructions but since we last did this 25 years ago all the people who knew the little tricks to really make it work are long gone.

      Another possibility is the files have been moved so many times over the years to make space for new material that nobody remembers where they are anymore.Probably locked up in some obscure SCIF, waiting to be moved again when the space is needed.

  • Desceptive title (Score:5, Informative)

    by DrBuzzo (913503) on Monday March 09 2009, @10:51AM (#27122103) Homepage
    The US has not forgotten how to make Trident Missiles. The missile is immaterial to the issue. The Trident missile can carry any number of warhead types and arrangements. The issue is the W76 warhead, which is used on many Trident missiles.

    The trident can just as easily be armed with the much newer and W88 without any modification and a mating adapter. It can be armed with non-nuclear warheads as well. It could even be topped with a small upper stage and payload to use it to launch a small satellite and not a weapon of any kind.
    • by fuzzyfuzzyfungus (1223518) on Monday March 09 2009, @09:57AM (#27121293) Journal
      Given the relative positions of "guns" and "butter" on ye olde national shopping list, you really don't want things to be bad enough that we can't afford guns. I agree that nukes are of limited relevance for a lot of issues more pressing than re-fighting the cold war in the paranoid imaginations of wrinkly old guys; but given the ability of tactically irrelevant weapons systems to continue to suck down massive funding for years or decades, I really don't want things to be so grim that they get cut; because that will mean than virtually everything else got the axe first.
      • by Torontoman (829262) on Monday March 09 2009, @10:01AM (#27121353)

        Wouldn't it be ironic if the missing ingredient in making Fogbank was Butter?

        Torontoman

      • Given the relative positions of "guns" and "butter" on ye olde national shopping list, you really don't want things to be bad enough that we can't afford guns.

        Or, you know, we could reprioritize the list. We might just decide that spending ten times more than any other nation on "guns" is too much, cut it down to, say, five times, spend some of the saving on "butter" and some on repaying the loans we started taking out back in the Reagan days to buy all those "guns", and tell the military-industrial complex to go on a fscking diet already.

      • What the funding should go towards is creating weapons that do effectively just as much damage without the radiation fallout.

        Not to put too fine of a point on it, but... Why?

        Is there any particular target you can think of that would be a viable candidate for a nuclear weapon strike? Cities would seem to be the most viable option, but we'd kill millions of innocents along with the bad guys. The brass once suggested that armies in open areas could be wiped out with a single nuke. However, no modern army is going to just line up and wait to be nuked short of a parade or show of force. (And definitely not in an unpopulated area.) Supercarriers and other large ocean-going vessels are good "soft" targets for nukes, but to what effect? Only the US floats supercarriers. With over a dozen in service plus hundreds of supporting vessels, all other navies are already outclassed.

        In the end, our nuclear arsenal serves one purpose: deterrence. Whoever might want to lob nukes out way is aware that we have nukes of our own to lob back. And we WANT those nukes to be as eco-unfriendly as possible so that they won't do any stupid calculations like "we'll take out 20 million of their's in exchange for 1 million of ours." Instead, the calculation should be, "if we kill 20 million of their's, we die."

          • BTW we have clean nukes they are called neutron bombs they are not science fiction.

            They're not really clean. They're "clean" from the perspective that they kill all the people while leaving the buildings *mostly* intact. However, they greatly increase the amount of radioactivity in the area. All those buildings that are penetrated with neutron radiation become radioactive themselves. A significant "rest" period is required before the city can be inhabited again. (Which is arguably unwise anyway.)

            Air-burst nukes are already relatively clean. Putting aside the fact that they mow over cities, the detonation event happening in mid-air leaves very little ground material in a highly radioactive state. Topsoil still should be replaced and drinking water checked for possible contamination, but the long term effects of an area that is properly cleaned up are usually fairly minimal.

            It's the interim before cleanup that's the big deal. With plenty of short-term radiation to go around, the bombs do a pretty good job of turning any area into a hell-hole. Which is a far more deterring effect than turning a city into a ghost town.

            Ground detonations are another matter altogether. Those are just about as nasty as you can get. The fallout does an extremely good job of making the area unlivable for a very long time. (As the US found out after it unhelpfully blasted dozens of islands into nothingness during nuclear testing.)

            But I have to go with Spaz on the idea that they should not be dirty nukes.

            You still haven't answered the question: WHY? What possible use could such weapons be?

            • by pvanheus (186787) on Monday March 09 2009, @11:13AM (#27122495)
              iraqbodycount.org is based on news media reports and they themselves state that: "Gaps in recording and reporting suggest that even our highest totals to date may be missing many civilian deaths from violence." How much undercounting that IBC does no one knows. So your figures are, as you say, bunk.
            • by mkcmkc (197982) on Monday March 09 2009, @11:15AM (#27122545)

              No offense, but stuff it. The US does not set out to kill as many people as possible.

              I certainly hope not. But unfortunately what one "set out to do" isn't what counts. What counts is what actually happens, especially when it was a forseeable result of one's actions. "I didn't mean to" is okay for children, but not so good for adults.

              91,060 - 99,433 [iraqbodycount.org] is the complete total for civilian deaths in Iraq.

              No, actually it's the number of documented deaths. That is, it's actually only a lower bound. The true number is certainly higher. No one knows how much higher. It would seem that there has been a studied effort by the governments involved not to determine the true number of men, women, and children killed.

              But having a hundred thousand people die due to being killed by their own people (#1 cause) and accidental deaths during live fire

              If these people would still have been alive had the US not acted, the US bears a responsibility. It might be true that this was the best of the available alternatives, but this case has not been seriously made at this point. "It's not our fault" is a pretty pathetic substitute.

        • by xch13fx (1463819) on Monday March 09 2009, @10:12AM (#27121513)

          And people wonder why I think the best way to secure peace is to get rid of the US...

          you mother fucking idiot. There has been war for thousands of years and will continue to be as long as there are haves and have nots. You think erasing the flash in history that is the U.S. is gonna fix the world? those mother fuckers with glass parking lots have been throwing rocks a lot longer then we have been dropping bombs....

        • the best thing to do in response to a nuclear attack by a terrorist organization would be to STFU and fucking NOT retaliate.

          I'm playing devils advocate in my post, I forgot to mention it. The problem is that trying to explain that to the POTUS and the joint chiefs would prove to be far more complex after millions of citizens were killed and millions more will die from the fallout.

          I would love nothing more than to have world unity and nothing but love all around, but look at after 9/11. Scorched fucking earth in Afghanistan. The American people called for retaliation, and they got it. Look in Israel, a few of their people are killed in suicide bombings and they level city blocks in neighboring countries. It always seems like the political figures take Sean Connery's line from The Untouchables to heart:

          He pulls a knife, you pull a gun. He sends one of yours to the hospital, you send one of his to the morgue. That's the Chicago way, and that's how you get Capone.

          • by Shakrai (717556) on Monday March 09 2009, @10:28AM (#27121759) Journal

            Scorched fucking earth in Afghanistan. The American people called for retaliation, and they got it.

            That's generally what happens when you provide logistical support and a base of operations to a terrorist organization that attacks a Great Power. You think Afghanistan would have come out better if Bin Ladin had murdered ~3,000 Chinese or Russians instead of ~3,000 Americans?

            It always seems like the political figures take Sean Connery's line from The Untouchables to heart:

            For better or worse that's how the world works. The only reason we don't see more of it is because nuclear weapons made total war too horrible to contemplate.

              • by Shakrai (717556) on Monday March 09 2009, @10:52AM (#27122107) Journal

                The Chinese and Russians are every bit as barbaric as Americans

                What you call barbarism I call self-defense. You don't respond to a terrorist attack by filing a lawsuit -- you respond by killing and/or imprisoning those responsible.

                "People sleep peaceably in their beds at night only because rough men stand ready to do violence on their behalf." -George Orwell

                • by Sj0 (472011) on Monday March 09 2009, @11:05AM (#27122335) Homepage Journal

                  "The origins of the group can be traced to the Soviet war in Afghanistan. The United States viewed the conflict in Afghanistan, with the Afghan Marxists and allied Soviet troops on one side and the native Afghan mujahedeen on the other, as a blatant case of Soviet expansionism and aggression. The U.S. channelled funds through Pakistan's Inter-Services Intelligence agency to the native Afghan mujahedeen fighting the Soviet occupation in a CIA program called Operation Cyclone."1 [wikipedia.org]

                  Cited, yo.

        • by Shakrai (717556) on Monday March 09 2009, @10:16AM (#27121565) Journal

          And people wonder why I think the best way to secure peace is to get rid of the US...

          You think the US is the only country that would respond in kind? Newsflash: Both the British and the French have reserved the right to respond to terror attacks with nuclear weapons. I suspect the Russians or Chinese would do so as well.

        • Reality.. (Score:5, Insightful)

          by evilkasper (1292798) on Monday March 09 2009, @10:21AM (#27121633)
          Nuclear weapons are not meant to "win". They are meant to ensure everyone loses. That in and of itself is the deterrent to using nuclear weapons.
        • by VShael (62735) on Monday March 09 2009, @10:27AM (#27121741)

          That's a logical, clearly reasoned and well thought out response to a hypothetical situation.

          Which is why it will never be done.

          9/11 was a far, FAR less traumatic event than a nuclear blast. And look at the fear-based trigger response that had, and the innocent people who took the brunt of that American fear response.

          Governments are made of people. And people are stupid.

        • by Lockblade (1367083) on Monday March 09 2009, @10:27AM (#27121745)
          If I had to choose whether to chance my family's safety or take out a family half a world away, would I do it? You bet I would. I value me and my family more than I value someone I have never seen nor met that wants to kill me.
        • by qbzzt (11136) on Monday March 09 2009, @10:39AM (#27121919)

          And people wonder why I think the best way to secure peace is to get rid of the US...

          I don't know why you think that, but the rest of the world doesn't exactly have a good track record in keeping the peace. Look at Europe before the US started stationing soldiers there in 1941 - two world wars. Or look at the parts of the world the US isn't interested in, such as Sub-Saharan Africa.

            • by xch13fx (1463819) on Monday March 09 2009, @10:53AM (#27122143)

              Around some parts, the word "patriot" is synonymous with "racist". Some countries are actually proud of other things than just owning the most guns.

              yea thats what the US is all about. we haven't contributed any technologies to the world, agriculture, charity. We all just sit at home cleaning our guns looking at our sisters funny. You sir sound like a racist that has America pinned.

            • by MadKeithV (102058) on Monday March 09 2009, @11:04AM (#27122311)
              Retaliation with nuclear weapons is more akin to telling the rape victim to wear a huge explosive belt and detonate it when a rapist strikes. Sure, you kill yourself and a potentially a bunch of bystanders, but at least you got the would-be rapist!
              Remember, an eye for an eye leaves the whole world blind. Or dead, in this case.
      • by TheRaven64 (641858) on Monday March 09 2009, @10:29AM (#27121763) Homepage Journal

        Yes, because making a rocket go a few extra thousand miles is such a challenge compared to developing a nuclear bomb.

        Actually, it is. The USA got nukes well over a decade before creating the first ICBM (1957). The first nuclear bombs were dropped from a plane. Developing the kind of aircraft that could get through the defences of the average nuclear power is even harder than developing an ICBM. You can't just load it into a conventional bomber and hope for the best. WW2-style bombing raids were only viable because the planes were cheap and it didn't matter if a load of them were shot down.

      • by Kell Bengal (711123) on Monday March 09 2009, @10:35AM (#27121867)

        because making a rocket go a few extra thousand miles is such a challenge compared to developing a nuclear bomb.

        Quite so. There are plenty of horrible, horrible non-nuclear weapons out there that can be delivered by ICBM that aren't nearly as difficult to develop. A good solid hit on downtown Washington and you've made as much as a political statement as a mushroom cloud. Nukes are only 'The Bomb' because of their emotional impact. Consider: people turned aircraft into weapons and now every airline passenger is treated like a criminal. Arguably more people have been effected by the World Trade Centre attacks than nuclear weapons. The sad truth is that you can kill people with a cricket bat if you try hard enough. Disposing of nukes, or guns or cricket bats won't stop violence. The only way to ensure lasting peace is through diplomacy and not engaging in international dipshittery.

        • by TnkMkr (666446) on Monday March 09 2009, @10:42AM (#27121941)

          Unless you have to overcome the counter measures and the chances that a few of your warheads may malfunction. We must calulate in a safety factor for annihlating the entire world. I think a factor of 5 to 10 (or maybe a little more) should be adequate.