Nuclear Weapon Design - Warhead Design Safety

Warhead Design Safety

Because even low-yield nuclear warheads have astounding destructive power, weapon designers have always recognised the need to incorporate mechanisms and associated procedures intended to prevent accidental detonation.

Gun-type weapons

It is inherently dangerous to have a weapon containing a quantity and shape of fissile material which can form a critical mass through a relatively simple accident. Because of this danger, the propellant in Little Boy (four bags of cordite) was inserted into the bomb in flight, shortly after takeoff on August 6, 1945. This was the first time a gun-type nuclear weapon had ever been fully assembled.

If the weapon falls into water, the moderating effect of the water can also cause a criticality accident, even without the weapon being physically damaged. Similarly, a fire caused by an aircraft crashing could easily ignite the propellant, with catastrophic results. Gun-type weapons have always been inherently unsafe.

In-flight pit insertion

Neither of these effects is likely with implosion weapons since there is normally insufficient fissile material to form a critical mass without the correct detonation of the lenses. However, the earliest implosion weapons had pits so close to criticality that accidental detonation with some nuclear yield was a concern.

On August 9, 1945, Fat Man was loaded onto its airplane fully assembled, but later, when levitated pits made a space between the pit and the tamper, it was feasible to use in-flight pit insertion. The bomber would take off with no fissile material in the bomb. Some older implosion-type weapons, such as the US Mark 4 and Mark 5, used this system.

In-flight pit insertion will not work with a hollow pit in contact with its tamper.

Steel ball safety method

As shown in the diagram above, one method used to decrease the likelihood of accidental detonation employed metal balls. The balls were emptied into the pit: this prevented detonation by increasing the density of the hollow pit, thereby preventing symmetrical implosion in the event of an accident. This design was used in the Green Grass weapon, also known as the Interim Megaton Weapon, which was used in the Violet Club and Yellow Sun Mk.1 bombs.

Chain safety method

Alternatively, the pit can be "safed" by having its normally hollow core filled with an inert material such as a fine metal chain, possibly made of cadmium to absorb neutrons. While the chain is in the center of the pit, the pit can not be compressed into an appropriate shape to fission; when the weapon is to be armed, the chain is removed. Similarly, although a serious fire could detonate the explosives, destroying the pit and spreading plutonium to contaminate the surroundings as has happened in several weapons accidents, it could not cause a nuclear explosion.

One-point safety

While the firing of one detonator out of many will not cause a hollow pit to go critical, especially a low-mass hollow pit that requires boosting, the introduction of two-point implosion systems made that possibility a real concern.

In a two-point system, if one detonator fires, one entire hemisphere of the pit will implode as designed. The high-explosive charge surrounding the other hemisphere will explode progressively, from the equator toward the opposite pole. Ideally, this will pinch the equator and squeeze the second hemisphere away from the first, like toothpaste in a tube. By the time the explosion envelops it, its implosion will be separated both in time and space from the implosion of the first hemisphere. The resulting dumbbell shape, with each end reaching maximum density at a different time, may not become critical.

Unfortunately, it is not possible to tell on the drawing board how this will play out. Nor is it possible using a dummy pit of U-238 and high-speed x-ray cameras, although such tests are helpful. For final determination, a test needs to be made with real fissile material. Consequently, starting in 1957, a year after Swan, both labs began one-point safety tests.

Out of 25 one-point safety tests conducted in 1957 and 1958, seven had zero or slight nuclear yield (success), three had high yields of 300 t to 500 t (severe failure), and the rest had unacceptable yields between those extremes.

Of particular concern was Livermore's W47, which generated unacceptably high yields in one-point testing. To prevent an accidental detonation, Livermore decided to use mechanical safing on the W47. The wire safety scheme described below was the result.

When testing resumed in 1961, and continued for three decades, there was sufficient time to make all warhead designs inherently one-point safe, without need for mechanical safing.

Wire safety method

One particularly dangerous warhead was Livermore's W47, designed for the Polaris submarine missile. The last test before the 1958 moratorium was a one-point test of the W47 primary, which had an unacceptably high nuclear yield of 400 lb (180 kg) of TNT equivalent (Hardtack II Titania). With the test moratorium in force, there was no way to refine the design and make it inherently one-point safe. Los Alamos had a suitable primary that was one-point safe, but rather than share with Los Alamos the credit for designing the first SLBM warhead, Livermore chose to use mechanical safing on its own inherently unsafe primary. The result was a safety scheme consisting of a boron-coated wire inserted into the hollow pit at manufacture. The warhead was armed by withdrawing the wire onto a spool driven by an electric motor. Once withdrawn, the wire could not be re-inserted. The wire had a tendency to become brittle during storage, and break or get stuck during arming, preventing complete removal and rendering the warhead a dud. It was estimated that 50-75% of warheads would fail. This required a complete rebuild of the W47 primaries. The oil used for lubricating the wire also promoted corrosion of the pit.

Strong link weak link

A strong link/weak link and exclusion zone nuclear detonation mechanism is a form of automatic safety interlock.

Permissive Action Links

In addition to the above steps to reduce the probability of a nuclear detonation arising from a single fault, locking mechanisms referred to by NATO states as Permissive Action Links are sometimes attached to the control mechanisms for nuclear warheads. Permissive Action Links act solely to prevent the unauthorised use of a nuclear weapon.