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DEPARTMENT OF THE NAVYI NAVAL SEA SYSTEMS COMMANDI WASHINGTON, D.C. 20362-5101

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INSENSITIVE MUNITIONSADVANCED DEVELOPMENT

FY 89 PROGRAM PLAN

APPROVED BY:

RICHARD E. BOWEN

i / "TABLE OF CONTENTS

SECTION IIMAD Program Overview I-i

E SECTIOIJ II... High Ricplosives -

Overview II-iCoordination and Technical Direction II-11General P1rpose plosives1 II-13Metal Accelerating Explosives, 11-15Underwater Explosives-,) 11-18Booster Explosives ,' 11-20

Explosive Processing Tchniques, 11-22Transition Efforts 11-24

i SECTION III-Ordnance , .f/ .

Overview III-iCoordination and Technical Direction 111-6Warhead D6signTchnology 111-7Advanced Xitigation T1chnology, 111-12Applied Materials and Shieldingp. i'.- 111-15Packaging and Container lechnology, 111-19Technology Transition/T&E Support 111-21

SECTION IVPropellants/Propulsion, -

Overview IV-lCoordination and Technical Direction IV-11Rocket Motors and targe Scale Testing, IV-13Propellants-, IV-15Advanced Plases, IV-19Mitigation ,Systems, v, IV-21Ignition ,ystems,. IV-23

AppendicesGlossary of Terms A-1Telephone Exchanges B-1I

Accesion For

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SECTION I

IMAD PROGRAM OVERVIEW

U SECTION I

5 IMAD PROGRAM OVERVIEW

Program Manager and Technical Director: Dr. R.E. Bowen; SEA-662,Naval Sea Systems CommandWashington, DC 20362-5101ITel: (703) 692-8728/

• •AV: 222-8728

INTRODUCTION: In 1984, the Chief of Naval Operations announced anew Navy policy which states that by 1995 all Navy munitions willbe designed to minimize the effects of unplanned stimuli whilereliably fulfilling their performance, readiness and operationalrequirements.

* This directive established a management structure (Figure I-1) with the Deputy Chief of Naval Operations (Surface Warfare)being responsible for oversight and coordination of the Navy'sInsensitive Munitions Program. He is assisted by the InsensitiveMunitions Council (IMC). The IMC is in turn supported in allaspects of program planning and execution by the InsensitiveMunitions Coordination Group (IMCG) chaired by the DeputyCommander for Weapons and Combat Systems, Naval Sea SystemsCommand.

Further, the Naval Sea Systems Command was designated as thelead SYSCOM for explosive material, energetic materials andinsensitive munitions. An office was established within NAVSEA(SEA-662) as the action desk to manage and technically direct theInsensitive Munitions Advanced Development (IMAD) Program and toprovide technical and administrative support to the IMCG. TheIMAD Program, which is the subject of this workplan, is anintegral part of the Navy's IM initiative.

OBJECTIVE: 'The objective of the IMAD Program is to develop anddemonstrate technology needed to reduce the vulnerability ofFleet munitions by reducing the severity of reactions resultingfrom fast cook-off, slow cook-off, bullet impact and fragmentimpact; also, to minimize the probability of sympatheticdetonation in storage and in use.- The requirements of NAVSEAINST8010.5, Technical Requirements for Insensitive Munitions, willhave to be met while maintaining required munition performancelevels.

MANAGEMENT STRUCTURE: The management structure of the Navy'sInsensitive Munitions Program is depicted in Figure I-1, thestructure of the Navy IMAD Program in Figure 1-2. Within theNavy IMAD Prog"am there_ are thrce ro-jacts. They are HijnExplosives, Ordnance, and Propellants/Propulsion. TechnicalCoordinators have been assigned for each project. The program

I I-1

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was organized to address the major components of a munitionsystem and still provide for crossovers in technology areasthrough the NAVSEA Program Manager. 5

NAVSEA-662 manages and technically directs the 6.3 IMADProgram. This encompasses the solicitation of work plans fromthe technical coordinators and other public and private agencies, Ithe evaluation of proposals, allocation of IMAD funds,prioritization of work, the establishment and maintenance ofchannels of communications between Navy Offices of PrimaryResponsibility (OPRs) and Technical Coordinators, and the overalldirection, review and documentation of work.

Navy OPRs have the responsibility to work with SEA-662 and Ithe laboratories to take full advantage of the technologygenerated under the IMAD Program as the goal of the IMAD Programis to meet the technology needs of these program offices.

The Technical Coordinators are responsible for theidentification of IM-related problems as foreseen by the OPRs andvarious experts in the field of munitions, the generation ofproposals, solicitation of proposals from other agencies and thedevelopment of an overall action plan to be evaluated by SEA-662. ITECHNICAL APPROACH: Ship survivability can be improved using thefollowing techniques, either individually or in combination: i)less sensitive energetic materials; -(2) mitigation devices orconcepts; 0) ordnance container hardening; 14) ship magazinehardening; -(5) weapon launcher hardening; and 6) upgraded damagecontrol/fire fighting. Item--(-, (2), and (3),are theresponsibilities of the NAVSEA IMAD Program.

The development of less sensitive energetic materials will Iprovide improved vulnerability characteristics across a range ofthreat stimuli. Where this technology cannot satisfy both IM andperformance requirements, mitigation concepts or a combination ofless sensitive energetic material and mitigation will be developed.Details of problems and approaches within each technical areaare discussed in Sections II, III and IV. 3

The general approach that has been taken by this program hasbeen to develop promising technology and evaluate it usinggeneric hardware. The generic hardware has been designed to Iprovide a low cost test vehicle which takes into accountrealistic design parameters. In this way, more large scaletesting can be done with better statistical significance of thetest results. In addition, it provides a baseline for comparingdifferent energetic materials in the same configuration ordifferent '-rfigurations using the tame energetic material. Inthese configurations, large scale safety, vulnerability and iperformance testing is done to evaluate the potential of a

1-2 1I

I specific technology to meet IM criteria while maintainingperformance. In addition, the effects of combined stimuli (i.e.heat and impact) will be investigated, within fundingconstraints, as part of a realistic threat scenario.

After evaluation in generic hardware, a technology is readyto be transitioned to a specific munition. Often times it is acooperative effort between the IMAD Program and the OPR. Within

these cooperative technology transition efforts, the R&Dcommunity adds to the data base and can refine the technology forreal applications thereby enhancing producibility for futuresystems. The OPR takes advantage of the experience of thetechnical staff and can reduce its risk in applying thetechnology. Everyone benefits; the IMAD Program, the OPR andfuture users.

Overall, it is considered critical that this program developimproved large-scale tests, hazard prediction techniques based onsmall scale testing and theoretical calculations, and improvedcorrelations between hazards and test studies to serve the needsof the OPRs and other technologists.

In order to meet the goals of this program, substantialimprovements in the technology of energetics and explosions(detonations) are needed. This will require the exploitation ofnew 6.1 and 6.2 technology, information exchange betweentechnologists in all areas of energetics and components R&D, aswell as coordination with appropriate programs of the DOD, DOE,private industry, universities, and allied nations. The IMADProgram must work with weapon OPRs to identify common munitioncomponents and hazard threats (Munitions Data Base), and to meettheir needs for improved technology through munitions hazard

* assessments.

PROGRAM DOCUMENTATION: The documentation requirements for theprogram are outlined in Figure 1-3.

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SECTION II

5 PROJECT ELEMENT: HIGH EXPLOSIVES

COORDINATOR: H. S. Haiss, Code RIOBNaval Surface Warfare CenterWhite Oak, Silver Spring, MD 20903-5000Tel: (202) 394-2490/AV 290-2490

I INTRODUCTION: Navy munitions use conventional high explosives toprovide destructive power for offensive and defensive purposes.New weapon systems frequently require explosives with improvedperformance while minimizing explosive weight and/or volume.Violent, unintentional reaction of high explosives in munitions,as a result of accidental exposure to hazardous environments orenemy attack, has demonstrated the need for explosives that reactmildly under these conditions. Special care must therefore betaken to ensure that demands for higher performance do not resultin the introduction of unacceptably hazardous materials that willdegrade overall Fleet effectiveness.

The U.S. Navy has active 6.1 (basic research) and 6.2(exploratory development) programs that generate new explosivestechnology to meet operational requirements. Products includerubbery, plastic bonded explosives (PBXs) that have been found toexhibit good vulnerability behavior, coupled with highperformance. The inability of the 6.2 explosives program toadequately support pilot plant scale-up and large-scale testingof new explosives led to the establishment of the 6.3 ExplosivesAdvanced Development (EAD) Program as a "new start" in FY78. Thisprogram was necessary to demonstrate that the new technologywill provide the expected benefits, that the new materials areproducible, and that there will be low risk when the newtechnology is incorporated into a munitions development program.In FY86, the EAD Program was integrated into the Navy's3 Insensitive Munitions Advanced Development Program (IMAD).

NAVY MISSION NEEDS: High explosives needed for future munitiondevelopments and for munitions upgrade have to display minimumsensitivity to inadvertent stimuli while providing maximumperformance. Furthermore, processing techniques and equipmenthave to be developed which will allow the economical loading ofhigh quality charges. More specifically, in order to reducemunitions vulnerability, explosives with substantially reducedsensitivity to shock stimuli, as encountered in hard targetimpact, high velocity fragment impact, and sympatheticdetonation, and with improved thermal stability, especially underslow cook-off conditions, have to be developed. In addition,explosive formulations have to be chemically stable duringstorage (particularly primaries).

I II-1

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Increases in performance are especially critical for warheads 3against "soft" targets (anti-air), where explosive fills withthe highest available fragment acceleration capability (-12,000ft/sec) are required, for underwater munitions, where a Isubstantial increase in performance is necessary, and for shapedcharge applications where armor penetration requirements cannotbe met with the latest "insensitive" explosives. It is also Ucritical that attention be focused on the production facilitiesthat will have to load munitions with new, improved highexplosives which require processing equipment and procedures thatare currently not available. For munitions under the cognizanceof the Single Manager for Conventional Ammunition (SMCA), theserequirements must be defined and provided to the SMCA to developthe necessary support and obtain approvals for equipment Iinstallation and construction of facilities.

STATUS OF TECHNOLOGY: During the past 30 years the sensitivity ofexplosives was substantially improved through the introduction ofPlastic Bonded Explosives (PBXs). Their good vulnerabilitybehavior, as compared to TNT based explosives, is attributed tothe incorporation of polymeric binders which resulted in nearlyvoidlesL', pliant, rubbery materials with fewer discontinuitiesand hence low energy breakup characteristics and reduced tendencyto form hot-spots. An additional feature of some composite PBXsis that fuel and oxidizers are physically separated, making itpossible to simultaneously increase chemical energy and decreasesensitivity.

In spite of these developments which resulted in overall improvedmunitions vulnerability, explosive fills that were selected oftenwill not pass the newly established safety criteria.

Vulnerability characteristics of specific munitions do notsolely depend on the specific explosive(s) employed, but are also Ia function of hardware design (i.e., degree of confinement/protectionprovided) and charge size. Thus, an explosive may pass slow cook-off in a small warhead under light confinement while it willfrequently detonate in larger weapons and/or under heavyconfinement. One of the recently developed PBXs , such as PBXN-109, will not sympathetically detonate when tested in 5"/54warheads (MK 64) but will react violently in a MK 83 GP bomb.

Recent progress in the formulation of general purpose explosives,which are optimized for both blast performance and fragmentation Ieffects, resulted in the qualification of PBXN-109 as the main

charge explosive for tho MK 83 GP bomb. Although the replacementof H-6 with PBXN-IC9 will solve most of the IM-related problems,it can only be considered an interim solution since thesympathetic detonation criterion cannot be met.

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m Development of moderately energetic explosives for fragmentaccelerating (mainly anti-air) warheads resulted in materialswith overall good vulnerability behavior under fast cook-offconditions and for critical fragment impact velocities of 7500-8000 ft/sec. However, new threat weapons develop much higherfragment velocities which will most likely produce explosionsor detonations. Explosives with maximum metal acceleratingcharacteristics for shaped charges and submunitions were in thepast mainly selected on a performance basis and the presentmunition fills (i.e., Octol, LX-14) need to be replaced withinsensitive explosives of equal performance.

In the area of underwater explosives, the development of PBXN-103 doubled the lethal volume of torpedo warheads with someimprovement in explosive sensitivity chararteristics. However,neither this explosive fill nor the later developed PBXN-105 andPBXW-115 satisfy all vulnerability criteria cited in NAVSEAINST8010.5. A needed increase in performance, together with improvedvulnerability characteristics, presents a challen-ing task for the

m explosives development community.

A reduction in the sensitivity of the main-charge explosivealone will not always solve munition IM problems. Some boostermaterials and detonation transfer explosives presentlyincorporated in munitions do not satisfy IM or future mission

requirements with respect to thermal stability and/orimpact/shock sensitivity and will have to be replaced to achievetotal munitions IM status. The development of high output, lowsensitivity booster materials for reliable ignition of "shock

m insensitive" main charge explosives will be a major problem area.

Table II-1 lists explosives which underwent advanced developmentwithin the recent past and either have been or are ready to betransitioned into weapon systems.

Difficulties with the loading of PBXs into conventional munitionsinitially limited the use of those materials to low productionrate, high technology weapons. More recent developments, however,have demonstrated that PBXs can be readily loaded into some highvolume production munitions (gun projectiles, bombs) at anaffordable cost. Present efforts in the area of continuousprocessing/extrusion should result in even more economicalloading of large volume munitions and will, in addition, allowthe incorporation of novel binder systems which cannot beprocessed with conventional mixing/cast/cure techniques . Aproblem still exists with respect to the high quality loading ofnew insensitive PBXs into small shaped charges and submunition.Present efforts on an injection loading system shows promise inthis area.

3 APPROACH: New technology emerging from the Navy's 6.2exploratory development program and, if considered feasible andadvantageous to the Navy' s effort, from other Services, DOE,

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Status/Availability Munitions

for Munitions Development Application*

Booster Explosives

PBXN-5 In-Service SM*/PHOENIX*/SPARROW*/20 MM*

PBXN-6 In-Service APAM BLU-77*

PBXW-7 Qualified/NOW QUICKSTRIKE EX-75 S&A*/PENGUIN*/GP Bomb Fuzing(FMU-139)/SAM-104 Fuze/MND/AMNE

I Initiation Train andPrimary Explosives

PBXN-301 In-Service Initiation Trains/

Explosives Logic

DXW-I Qualified/NOW Lead Azide ReplacementElectrical & Stab

IIIIII *In-Service or Engineering Development/Unmarked - projected application.

III

IIprivate industry, and allied countries will be introduced intoadvanced development. T&E studies will be conducted in three testphases. First, small scale laboratory studies to improveproducibility of the material will be conducted and initialproperties data will be generated via small scale experiments I(Phase I). Next, the explosives considered promising will bescaled up by the pilot plants (Phase II). This task also includesthe development of procedures and processing equipment needed toensure efficient and economical producibility. In Phase III thescaled-up explosives are subjected to large-scale vulnerabilityand performance tests in generic munition size hardware, and thetest data will be documented, specifications finalized, and data Iincorporated into an explosives properties document.

The main emphasis within the near future will be placed on the Idevelopment of a sympathetic detonation-resistant explosive forGP bombs and penetrating warheads (TOMAHAWK, HARPOON). Next inpriority are high performance, low sensitivity, metalaccelerating explosives for missile warheads (STANDARDMISSILE, PHOENIX, AMRAAM), shaped charge applications (SMAW,DRAGON, HELLFIRE, MK 50) and submunitions (ADVANCED CLUSTER, 16"Projectile). Although underwater explosives with increased Ibubble performance and reduced sensitivity are high on the Navy'spriority list, the transition of candidate explosives from the6.2 program is not expected until at least FY90. Meanwhileattempts will be made to identify a viable candidate by usingindustry expertise. To complete this broad approach, candidatefills for small warheads/projectiles, as well as less sensitivebooster explosives, have been identified and will be developed.

Additional efforts which are highly important to the overalleffort are the development of continuous processing and injection Imolding techniques which will allow for the safe and economical

processing of explosives and the efficient loading of highquality charges.

A vital part of the IMAD-HE Project is the transition of newexplosives and processing technology into engineeringdevelopment. Every possible effort will be made to familiarizImunitions offices with available technology and explosivedevelopments in progress. It will also be attempted to establishcooperative programs for explosives in advanced development inorder to accelerate the transition of critically neededtechnology.

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IPROJECT STRUCTURE: The IMAD High Explosives effort has beenorganized into seven core tasks as indicated below. The technicaltasks are listed in order of priority.

I Task NO. Title

2001 Coordination and Technical Direction2002 General Purpose Explosives2003 Metal Accelerating Explosives2004 Underwater Explosives2005 Booster Explosives2006 Explosive Processing Techniques2007 Transition Efforts

The project work is conducted primarily at three Navy facilities.A point-of-contact (POC) is officially designated at each ofthese as follows:

Facility POC

Naval Surface Warfare Center B. A. BaudlerDahlgren, VA (NSWC/D) and Code R12White Oak, MD (NSWC/WO)

Naval Weapons Center, China Lake , CA G. A. Greene(NWC/CL) Code 32601

Naval Ordnance Station, Indian Head, MD J. Changand Code 2730DYorktown,VA (NEDED) L.E. Leonardi Code 470A

Subprojects, tasks, and schedules are established and coordinatedat each Navy facility by the IMAD High-Explosives Project POCS.These in-house technical activities support the High Explosivescore tasks.

Principal investigators for the core tasks cited above, as wellas task descriptions, are listed in sections to follow.

PROJECT SCHEDULE: Schedules projected for the advanceddevelopment and transition of explosives and processingtechniques are shown in Figure II-1 (for further details see TaskDescriptions). As described above, the T&E on new explosives isconducted in three phases and, in general, five years areallowed for advanced development. The overall timespan may bereduced for high priority items or delays may occur due toprocessing difficulties or funding shortages. Some of theexplosives listed in Figure II-1 may also be dropped from theproject if initial evaluation results do not look promising.Similarly, schedules for processing and equipment studies dependlargely on the actual funding level. Significant milestones forFY89 and outyears are listed below:

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MAJOR MILESTONES

FY89

- Transition PBXC-129 into advanced development. 1st QTR

- Complete generic shaped charge performance tests 1st QTRusing PBXW-9, PBXC-126, PBXW-113, PBXW-119, PBXW-120, LX-14, and Octol 75/25 as main chargeexplosives.

- Complete small scale processing studies and 1st QTRtesting on PBXW-119 and PBXW-120 and select oneformulation for pilot plant scale-up.

- Select main charge explosives for HELLFIRE warhead 1st QTRand APOBS.

- Establish finalized composition for PBXC-18 (low ist QTR Ivulnerability booster explosive).

- Complete small scale testing of finalized PBXW-121 2nd QTR(bombfill).

- Complete small scale formulation of UW explosive 2nd QTRcandidates at Hercules, Inc.

- Complete processability studies on PBXN-109 with 2nd QTRthe 37mm continuous processor/extruder. I

- Complete performance testing on SMAW and DRAGON 2nd QTRWHs loaded with PBXW-9/PBXW-113.

- Start vulnerability and performance testing on 2nd QTRAPOBS (cooperative effort).

- Start loading of 16" gun submunition with several 2nd QTRPBXs; start performance and vulnerability testing.

- Process the first live mix with the 2" continuous 2nd QTRprocessor at NOS/IH ENEDED].

- Load generic test units (HWPs) and MK 82 bombs 3rd QTRwith PBXW-121 for large scale vulnerability andperformance testing.

- Complete small scale testing of contractor supplied 3rd QTRUW explosive candidates.

- Acquire 100 lbs of B-2188 (French booster 3rd QTRexplosive) from SNPE and start small scale testing.

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FY 89 (Cont'd)

- Select main charge explosive for SMAW and DRAGON 3rd QTR* warheads.

- Complete pilot plant scale-up studies on PBXW-121 4th QTR(bombfill).

I - Start large scale vulnerability studies on PBXW- 4th QTR121 loaded generic units and MK 82 bombs.

- Complete pilot plant scale-up studies on selected 4th QTRhigh performance explosive (PBXW-119/120).

I Complete scale-up of most promising UW explosive 4th QTRat contractor facility.

- Start loading of generic UW test units with 4th QTRselected explosive.

- Complete small scale processability studies on 4th QTRPBXC-18 and transition it to pilot plant scale-up.

- Complete design and installation of an injection 4th QTRloading system at NWS/Y.

- Provide support to the ADVANCED CLUSTER, QUICKSTRIKE, Cont.3 MK 98 (MND), and AMNE Programs.

- Establish transition efforts for MK 50, 75mm, and Cont.Follow-Through torpedo warhead.

FY90

Y- Complete vulnerability testing on generic unitsloaded with PBXW-121; document test results.

I - Start performance tests (blast, fragmentation) withPBXW-121 loaded generic units.

Load generic test units with high performanceexplosive (PBXW-119/120) and conduct large scalevlnerability tests.

I - Complete pilot plant scale-up studies on PBXC-129 andstart S&V testing.

S- Start large scale vulnerability and performance testswith selected UW explosive.

- Conduct processability studies on B-2188 (boosterexplosive).

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IFY90 (Cont'd)

- Transition B-2188 to the pilot plant for scale-up andloading of generic hardware.

- Scale up PBXC-18 to suitable batch sizes (pilotplant) and evaluate processing and pressingcharacteristics.

- Request qualification of PBXC-18 as a boosterexplosive and start S&V testing.

- Continue processing and injection loading studies onnew explosives with the small scale laboratory setups(NSWC/NWC).

- Conduct extended run studies with the 2" Readco atNOS/IH [NEDED].

- Develop the injection loading process at NOS/IH [NEDED] usinginert simulants and PBX explosives.

- Complete vulnerability testing on HELLFIRE warheads,APOBS, and 16" gun submunition (cooperativeprograms).

- Support MK 50, 75mm, Follow-Through, ROCKEYE, andADVANCED CLUSTER programs. 3

- Establish additional transition efforts.

FY91-92 I- Complete performance testing on generic units and MK

82 bombs loaded with PBXW-121; document test results.

- Transition GP-bombfill to weapon developer.

- Start transition (cooperative) efforts with the iHARPOON and TOMAHAWK Program Offices.

- Complete advanced development of PBXW-119/120, Idocument test results, and transition explosive toweapon developers.

- Conduct large scale performance and vulnerabilitytests on generic units loaded with PBXC-129/initiatetransition efforts.

- Complete large scale testing of UW explosivedeveloped under contract and document test data;start transition efforts. I

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FY91-92 (Cont'd)

- Transition high bubble energy UW e.-Dlosives into* advanced development.

- Complete processability study and pilot plant scale-up of high bubble energy UW explosive.

- Conduct large scale cook-off and performance tests ongeneric booster designs loaded with PBXC-18 (NWCdeveloped), B-2188, and PBXW-7.

- Initiate transitioning of PBXC-18 and/or B-2188 to3 munition developers.

- Conduct continuous processing studies on melt castexplosives with the 2" Readco at NWS/Y.

- Integrate the NOS/IH ENEDED] injection loading system with the 2"Readco continuous processor.

- Complete transition efforts for SMAW, DRAGON,HELLFIRE, APOBS, and 16" gun submunition-

- Continue to support NAVAIR and NAVSEA in theselection of low vulnerability explosives for IMmunition designs.

LONG RANGE PLANS (BEYOND FY92): Long range plans for the IMAD -HE Project depend to a large extent on the technology emergingfrom the 6.2 Explosives Block Program. This may have to beaugmented by soliciting ideas from private industry and/orthrough adoption and possible modification of explosivecandidates and processing techniques developed by other Services,DOE, or allied countries.

New munitions will require explosives that provide higherperformance and better vulnerability characteristics than are nowavailable. One way this can be achieved is through new warheaddesigns, including a variety of directional warheads and use ofspecial multioption, multipoint initiator systems. Such designswill require close cooperation between the IMAD High Explosiveseffort and munition developers to match explosives propertieswith those high technology warhead concepts. Specific technologyneeds are for explosives with substantially higher performancefor anti-air missiles, torpedoes and anti-armor munitions,explosives with improved thermal stability for high performancewarheads or space applications, deformable explosives, andspecial purpose binary explosives. New 6.2 development projectsare focused on these future Navy requirements and include work onfluorocarbon binder formulations, new metal additives in placeof aluminum powder, special charge designs, and reactive casematerials.

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Task Title: Coordination and Technical DirectionTask Number: 2001Principal Investigators: H. Haiss, NSWC/WO, Code RIOB, X2490

B. Baudler, NSWC/WO, Code R12, X1787G. Greene, NWC/CL, Code 32601, X7502J. Chang, NOS/IH, Code 2730D, X4453L. Leonard, NOS/IH [NEDED]/Y, Code470A, X4716

I OBJECTIVE: Provide coordination and technical direction of theIMAD HE project. Coordinate with related work being undertaken bythe other Services, by private industry, and by other nations.Interact with the 6.2 Explosives Exploratory DevelopmentProgram and with weapon program offices (OPRs) to expeditetransition of all weapons to insensitive status. Attend necessarymeetings and conferences, prepare/present plans and reports andrespond to various requests by the Sponsor.

BACKGROUND: The original EAD Program was set up to provide abridge for transitionina technology from the 6.2 technologybase into 6.4 munitions development. It was also intended toreduce the overall cost of introducing new technology into Fleetweapons. To do this effectively, it is necessary to coordinatehigh explosives efforts closely with the technology base 6.1 and6.2 energetic materials programs and with munition developmentoffices. It is also important to coordinate with relatedtechnical activities in this and in other countries to uncoverthe most promising new technology, to direct efforts into themost fruitful areas, and to avoid duplication of work.

I APPROACH: Technical direction and coordination ere theresponsibilities of the IMAD High Explosives TechnicalCoordinator (TC) and the Points-of-Contact (POCs) at the threefunded Navy facilities, NSWC/D and WO, NWC/CL, and NOS/IH. Activecontacts are maintained with the other Services, the SMCA, DOE,private industry, and other countries. Work at the two pilotplants and the R&D Centers is woven into a single, coordinatedactivity. New explosives are initially assessed at eitherNSWC/WO or NWC/CL. They are then turned over to NOS/IH for pilotplant scale-up, and later to be loaded into generic test units.Large-scale vulnerability and performance tests and laboratorycharacterization is divided betw.ieen NSWC and NWC/CL. Efforts totransition new technology into munition development programs areusually initiated and conducted by either NSWC or NWC. Workpriorities and schedules are established by the TechnicalCoordinator following discussions with sponsor and POCs.Technical data on explosives are obtained and evaluated by teamsof project workers from the different laboratories.

Personal interactions, participation in working groups, andpresentations at technical meetings are used to exchangeinformation and to coordinate with other related technical

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activities. The technical direction of the Navy's 6.1, 6.2, and I6.3 explosives R&D programs is the responsibility of NSWC/WOEnergetic Materials Division (Code R10) staff personnel. Thesetechnical coordinators interact frequently. Additional Icoordination of the high explosives development effort isaccomplished through the exchange of data and discussions in manymeetings, including NAVSEA technical reviews, the Working Party ifor Explosives (WPE) under the Joint Ordnance Commanders Group,Data Exchange Agreements (DEAs) with various European allies,the Technical Cooperation Panel (TTCP WP-I; USA, UK, Canada,Australia, and New Zealand), the NATO AC/310 Sub-group 1 onExplosives, and meetings sponsored by professional groups(such as the American Defense Preparedness Association).

PROGRESS (FY88): Following substantial funding reductions duringFY88, the IMAD-HE program plan, priorities, and milestones wererevised. Several subtasks in the areas of data base Icomputerization, revision of test manuals, test/assessmentmethodology, processing technology, and predictive efforts wereterminated. Large scale testing and transition efforts weresubstantially reduced and the formulation of underwater Iexplosives under contract with private industry was largelyshifted to FY89. The funding of the highest priority task (GPbombfill), however, was maintained at the originally planned Ilevel.

Navy IM requirements, technology developments, and availabletechnology options were presented to NAVSEA/NAVAIR PMs, Army and IAir Force personnel, and representatives of private industry andallied nations. IMAD-HE Project personnel participated in NSWCExplosives Selection Committee meetings and attended 6.2 mExplosive Block Program meetings in order to keep up withemerging technology.

PLANS (FY89-FY92): Plans under this task are aimed towardsdevelopment of explosives and processing technologies for themost critical munition fills, either through in-house efforts orcontracts with private industry. The transition of new technologyto weapon programs will be actively pursued and communicationwith 6.2 community, other IMAD projects, DOE, other Services, andrepresentatives of allied countries will be continued.

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Task Title: General Purpose ExplosivesTask Number: 2002Principal Investigators: J. Leahy, NSWC/WO, Code RII, X4859

T. Atienza Moore, NWC/CL, Code 3264,7530J. Chang, NOS/IH, Code 2730D, X4453M. R. Senn, NOS/IH (NEDED]/Y, Code470H, X4717

OBJECTIVE: Development of a sympathetic detonation resistantmain charge explosive fill for GP bombs and heavy-wall peretrators.

BACKGROUND: Recent progress in the formulation of generalpurpose explosives, which are optimized for both blast andfragmentation effects, resulted in the qualification of PBXN-109as a main charge fill for the MK 83 GP bomb. Although thereplacement of the present H-6 bombfill with PBXN-109 will solvemost IM related problems, it can only be considered an interim

solution since the sympathetic detonation criterion could not bemet. Similarly, several heavy wall penetrators, such as theHARPOON and TOMAHAWK warheads, would greatly benefit from thedevelopment of an explosive with substantially reducedsensitivity to thermal, impact, and shock stimuli.

APPROACH: The key to the formulation of a sympathetic detonationresistant bombfill appears to be the elimination or, at least,substantial reduction of the RDX content, as the most shocksensitive component of present GP explosives. Since performanceshould be kept at or near the level of H-6 and PBXN-109, only alimited number of oxidizers are available if the cost of the fillis to be kept at an affordable level. After considering feasiblecandidates, such as Nitroguanidine (NQ), Nitrotriazolone (NTO),and Amino-dinitrobenzo-furoxan (ADNBF), NTO was selected. Thisdecision was primarily based on data generated on this ingredientat the DOE and by French scientists. In order to accommodatelarge volume production, a melt-cast binder system based on athermoplastic elastomer (TPE) was selected for initialformulation efforts. Intentions are to develop a sympatheticdetonation and cook-off resistant explosive based mainly on NTOas oxidizer and aluminum as metallic fuel. In order to meet orapproach the performance of H-6/PBXN-109 and to ensure reliableinitiation, it is anticipated that the solids loading will haveto be maximized and that a low percentage of nitramine (RDX) willhave to be incorporated. Following small scale producibilitystudies and testing, the resulting formulation will betransitioned to a Pilot Plant for scale-up and loading of generichardware and MK 82 bombs. Subsequently, large scale performanceand vulnerability tests will be conducted and cooperative effortswith weapon programs will be initiated.

PROGRESS: While FY87 formulation efforts concentrated on a melt-cast bombfill with solids loads ranging from 80-84%, it became

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obvious during the 4th quarter that the thixotropic character of UTPE based mixes would not allow any further increase in solids,which seemed a prerequisite to approaching PBXN-109 performancewhile maintaining a relatively low percentage of nitramine (RDX).Therefore, a cast-cure binder system based on plastician (IDP)and hydroxyterminated polybutadiene (HTPB) was selected forfurther mixing studies. This change resulted in the successful Uprocessing of an 88% solids, low nitramine content explosivewhich can be reliably initiated to yield high order detonationsin 4-5" diameter unconfined charges. This formulation, which hasbeen designated PBXW-121, has been successfully mixed and cast inbatches of up to 22 pounds. Firings of 3-5" diameter (16" long)cylinders, both confined and unconfined, showed a criticaldiameter of 3-4" for this low nitramine (5-10%) composition and Idetonation velocities similar to PBXN-109. Attempts to initiatean all-NTO (0% RDX), unconfined 5" diameter charge failed, whilethe identical charge under heavy steel confinement detonated with ia rather low average velocity (5700 m/sec). For the remainder ofFY88, fine tuning of the basic composition and determination ofthe critical initiation pressure, as well as preliminaryperformance tests (arena test/cylinder test) and a sympatheticdetonation test, all using 8" diameter charges under heavyconfinement, are planned.

PLANS (FY89-FY92): Plans and major milestones for the task by

fiscal year are as follows:

FY89

- Complete small scale testing of finalized PBXW-121 formulation.

- Complete Pilot Plant scale-up studies.

- Procure 3000 lbs of NTO under contract. 3- Request Qualification of PBXW-121 as a main charge explosive.

- Load generic hardware and several MK 82 bombs for large scaletesting.

- Start large scale vulnerability tests using heavily confined Icharges.

FY90 i

- Complete vulnerability testing on generic units and MK 82 bombsloaded with PBXW-121. i

- Document vulnerability test results.

- Start performance tests (blast, fragmentation) using generic Itest hardware and MK 82 bombs.

11-18 3I

II FY91-92

3 - Complete performance testing and documentation.

- Transition explosive to weapon developer.i

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Task Title: Metal Accelerating Explosives Task NTask Number: 2003Principal Investigators: T. Spivak, NSWC/WO, Code R12, X1184

T. Atienza Moore, NWC/CL, Code 3264,X7530L. Newman, NOS/IH, Code 2730A, X4635M. R. Senn, NOS/IH [NEDED]/Y, Code U470H, X4717

OBJECTIVE: Advanced development of high-performance explosives 1for anti-air warheads, shaped charge designs, and submunitions.

BACKGROUND: In the past, explosives with optimized metal 1accelerating capability for high-performance anti-air warheadsand shaped charge designs were primarily selected on aperformance basis, disregarding vulnerability characteristics. IPresently employed explosives such as Octol, LX-14, A-5, and A-3need to be replaced with explosives of equal performance andreduced vulnerability. The development of castable, moderatelyenergetic explosives such as PBXN-106, PBXN-107, and PBX(AF)-108 Ifor fragment accelerating (mainly anti-air) warheads resulted inmaterials with overall satisfactory vulnerability behavior underfast cook-off conditions and for fragment impact velocities of U7500-8000 ft/sec. The criterion for slow cook-off, however, couldnot be met and sympathetic detonation behavior depends on thesize and confinement of the warhead. The later developed PBXW-113 and PBXW-114 display similar vulnerability behavior withimproved performance. Further increases in performance with, ifpossible, simultaneous reduction in sensitivity are highlydesirable.

APPROACH: During FY85 two new high-performance explosives -the castable PBXC-126 (formulated with an energetic binder Isystem) and the pressable PBXW-9 (based on a Hycar/DOA binder)

were transitioned into the 6.3 Advanced Development Project.These explosives are expected to show improved vulnerabilitybehavior and performance as compared to PBXW-II3 and to approachthe performance of Octol 85/15 and LX-14. The latter arepresently being considered for new shape charge designs based ontheir exceptional performance characteristics only. Small-scale Iproducibility studies and preliminary sensitivity and performancetests will be conducted on both PBXW-9 and PBXC-126. They willbe followed by pilot plant scale-up, loading of generic hardware, Uand large-scale safety and vulnerability testing in generichardware such as heavy wall penetrator units, naturallyfragmenting test units, and generic shaped charge designs.Performance tests conducted within the IMAD-HE Project willconcentrate on shaped charge penetration testing. It is expectedthat these explosives will be ready for transitioning to weaponprograms by the end of FY88. I

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In order to satisfy demands for even higher performance, lowvulnerability explosives, promising new candidates emergingfrom the 6.2 Exploratory Development Program will be transitionedto 6.3 Advanced Development during the FY88-89 timeframe.

PROGRESS: Large scale vulnerability tests on PBXW-9 and PBXC-126were completed. Both explosives reacted mildly under variousconfinements when exposed to fast cook-off. Slow cook-offcondition resulted in detonations for PBXC-126 loaded generictest units while PBXW-9 showed only burning reactions, eve underheavy confinement. Multiple bullet impact caused a mixture ofdeflagration and burning reactions. As to be expected for highperformance explosives, Multiple Fragment Impact (MFI) led todetonations at fragment velocities above 7000-7500 ft/sec andboth explosives sympathetically detonated in MK 64 configurationat PD50 s of 3-4 inches.

Preliminary performance tests (FY87) with both explosives in SMAWwarheads led to penetration depths which fell approximately 5-10%short of results obtained with Octol 85/15. Since consistentprocessing problems were encountered at this stage with bothformulations (inhomogeneities and voids), it is hoped that theseresults can be improved upon. During FY88 processing difficultieswere solved and PBXW-9 was scaled up to a 3000 pound batch byHolston AAP with excellent results. Performance tests withgeneric 3.2" shaped charges filled with PBXC-126 and PBXW-9 willtherefore be conducted during the remainder of FY88 and theresults compared with those obtained on LX-14 and Octol loadedgeneric test units.

I Processing studies on PBXW-119 (energetic polymer/nitroplasticizer)and PBXW-120 (fluorocarbon polymer/energetic plasticizer) are inprogress. It is expected that both of these high-performanceexplosives will also be tested in the generic shaped chargeconfiguration during the remainder of FY88. One of theseformulations will be selected for Pilot Plant scale-up during thefirst quarter of FY89.

PLANS: Plans and milestones for the task by fiscal year are as* follows:

FY89

3 - Transition PBXC-129 (moderate to high performance, lowvulnerability explosive) into advanced development, qualifyfinalized composition and transition to Pilot Plant.

- Complete generic shaped charge performance tests on unitsloaded with LX-14, Octol 75/25, W-9, C-126, W-113, W-119, andW-120.

- Complete vulnerability tests on generic shaped charges loadedwith W-9 and C-126.

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FY89 (Cont'd) m

- Complete small scale processing studies and testing on PBXW-119and PBXW-120 and select one formulation for Pilot Plant scale-up.

- Complet- Pilot rlant scale-up studies on selected high

performance explosive (PBXW-119/120).

FY90 3- Load generic test units with PBXW-119 (120) and conduct large

scale vulnerability and performance tests.

- Complete Pilot Plant scale-up studies on PBXC-129 and start S&Vtesting.

FY91-92

- Complete advanced development of PBXW-119 (120) and documenttest results.

- Complete S&V testing of PBXC-129; conduct performance tests andinitiate transition efforts.U

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U Task Title: Underwater ExplosivesTask Number: 2004Principal Investigator: Joel Gaspin, NSWC/WO, Code R14, X2204

OBJECTIVE: Advanced development of a low vulnerability, high3performance explosive for underwater applications.BACKGKOUND: In the area of underwater explosives, thedevelopment of PBXN-103 doubled the lethal volume of torpedowarheads with some improvement in explosive sensitivitycharacteristics. However, neither PBXN-103 nor the laterdeveloped PBXN-105 which displays performance similar to PBXN-103or PBXW-115 with somewhat lower performance and marginallyimproved vulnerability, satisfy the IM criteria cited inNAVSEAINST 8010.5. In addition to improved vulnerability,improvements in performance, specifically in bubble energy, areneeded. Since the transitioning of a promising candidateexplosive from the Navy's 6.2 program is not expected until 1991,an attempt is being made to identify a viable candidate using the

*expertise of private industry.

APPROACH: Proposals on the formulation and scale-up of highperformance, low vulnerability underwater explosives will besolicited from private industry. Following the evaluation ofproposed efforts, one or more contractors will be selected forthe formulation of preliminary candidate explosives. While theactual process development will be done by industry, IMADpersonnel will assist in initial formulation efforts and willevaluate the resulting explosives in-house by conducting smallscale sensitivity and performance tests. It is expected that,following compositional adjustments, one proritiing explosive willbe selected for scale-up and loading of generic hardware by thecontractor. Generic test units will be supplied by the IMAD-HEProgram and large scale tests will be conducted in-house.

Should a high bubble energy underwater explosive withsubstantially improved performance and vulnerabilitycharacteristics evolve from the in-house 6.2 ExploratoryDevelopment Program during the FY90-92 timeframe, it will be3 transitioned to the 6.3 phase for advanced development.

PROGRESS: Toward the end of FY87, a contract was awarded toMEGABAR Corporation to start the development of emulsion typeexplosives for underwater applications. However, during the firstquarter of FY88, MEGABAR became involved in a litigation processwith IRECO Corporation regarding the ownership of microcellulartechnology, which ultimately resulted in the closing of MEGABAR.

During the third quarter of FY88, a contract was awarded toHercules, Inc. For the remainder of this fiscal year thisincrementally funded project is expected to concentrate on aliterature search specific to underwater explosives, consultation

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with Navy and DOE experts, and formulation and testing of a highstrain, urethane based energetic binder system.

PLANS (FY89-FY92): Plans and major milestones for this task by Ifiscal year are as follows:

FY89

- Complete small scale formulation of several UW explosivecandidates at Hercules, Inc. 3

- Complete small scale testing of contractor supplied

formulations at NSWC. 3- Complete scale up of most promising candidate.

- Load generic hardware for large scale vulnerability andperformance testing.

FY90

- Start large scale vulnerability and performance tests ingeneric hardware. i

FY91-92

- Complete large scale testing and document test data.

- Start transition to underwater weapon systems. i

- Introduce high bubble energy UW explosive into 6.3 advanceddevelopment. i

- Complete processability studies and scale-up of high bubble UWexplosive.

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U Task Title: Booster ExplosivesTask Number: 2005Principal Investigators: T. Atienza Moore, NWC/CL, Code 3264,

X-4530R. Moffett, NSWC/WO, Code R12, X1788

3 OBJECTIVE: Development of new booster materials with improvedvulnerability characteristics.

BACKGROUND: The booster materials currently qualified for use inNavy weapon development programs do not fully achieve desiredvulnerability characteristics, particularly in the cook-offenvironment. ADNBF-based explosive has demonstrated unusuallybenign reactions, even in a severely confined cook-offenvironment, while providing output energy and sensitivity levelssuitable for use in a booster material. A formulation,designated PBXC-18, has been developed under the ExploratoryResearch (6.2) Program using ADNBF explosive with an inert binderbased on an ethylene-vinyl acetate copolymer which appears toprovide a significant improvement in vulnerabilitycharacteristics. This material has been evaluated to a pointwhere it is ready to be developed by the IMAD-HE Program.

As part of their program to develop less sensitive munitions, theFrench have formulated an inexpensive, castable, cook-offresistant, plastic bonded (PBX) booster explosive. Theformulation, designated B-2188, is described as having overallgood vulnerability behavior, initiation characteristics, andboostering power. Based on this information, the IMAD-HE Programwill evaluate B-2188 and assess its value and potential to solvesome of the Navy's IM problems.

APPROACH: PBXC-18 will be further developed and evaluated withinthe IMAD-HE Program and, as soon as appropriate, it will betransitioned to the pilot plant and qualified for larger scaletesting in generic and weapon system hardware. Initial activitieswill center on validating the composition and conducting smallscale sensitivity, performance, and safety tests to more fullycharacterize the material. A draft specification will beprepared, and a report will be written, covering the developmentof PBXC-18 and such other information as may be necessary totransition this material to the pilot plant. Sufficient ADNBFexplosive will be produced to provide a supply for this programand some other formulation development programs currentlyunderway.

Through the existing DEA-A-77-F-1221 with France, contacts willbe established with SNPE in order to obtain more information onthe sensitivity, performance characteristics, and producibilityof B-2188 and 200 pounds of this formulation will be purchasedfor preliminary evaluation and possibly qualification testing. Ifthe generated data are favorable, the explosive will be

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transitioned to advanced development and compared to in-housedeveloped formulations (PBXW-7, PBXC-18) via large scalevulnerability and performance testing in generic hardware.

PROGRESS: This is a new start.

PLANS (FY89-FY92): Plans and major milestones for this task byfiscal year are as follows:

FY89

- Establish finalized composition for PBXC-18.

- Complete small scale processability study and testing.

- Transition PBXC-18 to the pilot plant for scale-up.

- Acquire 200 lbs of B-2188 from SNPE and conduct small scalevulnerability and performance tests.

- Qualify B-2188, if test data look promising, and negotiate with

French Government to transfer technology to the U.S.

FY90

- Scale up PBXC-18 to suitable batch sizes (pilot plant) andevaluate processing and pressing characteristics.

- Request qualification of PBXC-18 as a booster explosive andstart S&V testing.

- Conduct processability study on B-2188.

- Transition B-2188 to the pilot plant for scale-up and loadingof generic hardware.

FY91-92

- Conduct large scale vulnerability and performance tests ofPBXC-18, B-2188, and PBXW-7 in generic hardware and comparetest data.

- Depending on outcome of large scale test series, initiatetransition of PBXC-18 and/or B-2188 to various weapon programs.

IIiI-26 Ii

...,, , , ,I [

K Task Title: Explosive Processing TechniquesTask Number: 2006Principal Investigators: F. Gallant, NSWC/WO, Code RII, X2861

T. Mahoney, NWC/CL, Code 3262, X7567K. Newman, NOS/IH [NEDED]/Y, Code3 470F, X4718

OBJECTIVE: Develop new processing techniques to load high qualityinsensitive PBXs economically.

BACKGROUND: Difficulties with the processing and loading of PBXsinto conventional munitions initially limited the use of thosematerials to low production rate, high technology weapons. Morerecent developments have demonstrated that PBXs can be readilyloaded into some high volume production munitions (i.e., MK83 GP bomb) at an affordable cost. Problems, however, stillexist with respect to the high quality loading of relatively highviscosity PBXs into small shaped charges and submunitions andwith the processing of novel binder systems, using conventionalmixing/cast/cure techniques. Present efforts in the areas ofcontinuous processing/extrusion and injection loading are aimedtowards correcting these shortcomings.

I APPROACH: Equipment that needs to be investigated and adapted tothe processing of PBXs includes continuous processors andprocessor/extruders which are commercially available, andinjection loading systems which are presently used by privateindustry for the processing of various plastic materials and byKansas AAP for the loading of small munitions with low viscosityexplosives (i.e., Octols). Both techniques will be developedand studied on a small scale at the laboratories, followed byprocessing demonstrations in larger setups at the pilot plants.Ultimately it is intended to transition the continuous processingtechnology to the SMCA for large scale production loading.Submunitions, shaped charges, and small missile warheads will beloaded with PBXs at a Navy production facility using theinjection loading technique.

PROGRESS: Following the successful processing of PBXN-106 andPBXN-109 in a 37mm Werner Pfleiderer continuous mixer/extruderunder contract (ICT/FRG) within the FY86/87 timeframe, theinstallation of a similar setup was completed at NSWC and thefirst live mix (PBXN-106) was processed during the second quarterof FY88. Installation of the modified 2" Teledyne Readcocontinuous processing system at NOS/IH [NEDED] was also completed.Trial runs with inert PBX simulants will be conducted during the

* remainder of this fiscal year.

A manually operated, small scale injection loading system atNWC/CL was first tested with live explosive near the end of FY87by loading Rockeye bomblets with PBXC-126. Since then theconversion to an automated control and data acquisition system

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has been accomplished and a vacuum shroud large enough to 5accommodate warheads up to the size of a DRAGON has been added.The design of a larger scale injection loading system to beinstalled at NOS/IH [NEDED] was continued. NEDED intends to adopt Ia modification of the Kansas AAP injection loader which wasoriginally designed for the processing of low viscosityexplosives. During FY88, Kansas AAP completed modifications and Iconducted trial runs with inert PBX simulants.

PLANS (FY89-FY92): Plans and major milestones for this task byfiscal year are as follows: IFY89

- Conduct processability studies on various explosives with the37mm continuous mixer/extruder at NSWC. i

- Process several explosives with the small scale injectionloader at NWC/CL and load submunitions.

- Develop processing and data acquisition parameters for the icontinuous processing of PBXN-109 in the 2" continuousprocessor at NEDED. 5

- Develop an in-line composition analysis system for the 2"processor. 5

- Complete the design and installation of an injection loadingsystem at NEDED.

FY90 i- Continue processing and injection loading studies on new

explosives with small scale laboratory setups (NSWC/NWC). I- Continue process development for the 2" continuous processorand develop a loading system NEDED.

- Conduct extended run studies to prove-out the process (2"Readco).

- Develop the injection loading process at NEDED using inertsimulants and PBX explosives.

FY91-92

- Conduct continuous processing studies on melt-cast explosives(2" Readco).

- Continue testing of injection loading system at NEDED.

- Integrate the NEDED injection loading system with thecontinuous processor. i

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I Task Title: Transition EffortsTask Number: 2007Principal Investigators: L. Montesi, NSWC/WO, Code R12, X2039

T. Atienza Moore, NWC/CL, Code 3264,X7530L. Newman, NOS/IH, Code 2730A, X4453L. Leonard, NOS/IH [NEDED)/Y, Code470A, X4718

OBJECTIVE: Establish efforts with weapon development offices andother technology/program offices to facilitate the transition ofnew explosives technology into munition development programs.

I BACKGROUND: The transfer of new explosives technology intomunitions development is sometimes impeded by inadequatecommunication between the explosives developing community and themunitions developing community. In addition, there often exists alack of confidence on the part of the munition developer in newtechnology. Yet, many instances will arise when both the IMAD-HEProject and the Weapons Program can mutually benefit fromcombining efforts. The new technology must be developed to thepoint that it is considered to be state-of-the-art and must bedemonstrated to be relatively low-risk for munitions development.The efficient coupling of new high explosives technology with newfuze and warhead technologies provides the mechanism fordeveloping the best technical and most economic munition designs.

APPROACH: Dialogs are established between the IMAD-HE Project andmunition development offices to determine the developer's needsand to describe available technology. Where new high explosivestechnology is available to meet the defined requirements, eitherthe technology will be transitioned directly, or if there is aconcern regarding its readiness, a program will be negotiated toshare costs for demonstrating the new technology. Typical IMADProgram contributions will include provision of technical dataand recommendations, generation of draft material/processingdocumentation, assistance with the loading of initial test units,testing, and test evaluation.

PROGRESS: Transition efforts during FY88 included therecommendation and testing of less sensitive explosives for SMAW,DRAGON, HELLFIRE, APOBS, MK 82 fuze (FMU-139), M-42/M-77submunition, and ADVANCED CLUSTER Submunition (BLU-97), as wellas production loading support for the MK 83 bomb (PBXN-109) andqualification testing of two DOE explosives (LX-07/LX-14). Mostof these projects were continuations of efforts initiated duringthe FY86/87 timeframe. During FY88, penetration requirementswere met for SMAW (PBXC-126, two of three attempts), DRAGON(PBXW-113), and HELLFIRE (PBXW-113). Work on the M-77 grenade(ZUNI) was discontinued and the effort shifted to the virtuallyidentical M-223/M-42 submunition used in the 16" projectile.Performance and SD tests on units loaded with PBXC-126 showed

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excellent results. A series of vulnerability tests on BLU-97 i(ADVANCED CLUSTER) bomblets proved that PBXs (i.e., C-126, AF-108, W-113, N-106, N-107) are superior in their SD behavior tothe standard Cyclotol load, and fast cook-off tests resulted in mburning reactions only. During the remainder of FY88, additionalpenetration tests will be conducted with HELLFIRE (W-113, C-126,W-9) and DRAGON warheads (W-113). In addition the performance of 3PBXW-9, PBXC-13, AND PBXW-7 in the M-42 submunition will beevaluated.

PLANS (FY88-FY92): Plans and major milestones for this task by ifiscal year are as follows:

FY89 I- Complete performance tests on SMAW, DRAGON, and HELLFIREwarheads loaded with PBXW-9, PBXC-126, and PBXW-113. i

- Select main charge explosives for SMAW, DRAGON, HELLFIRE, andAPOBS.

- Load 16" gun submunition with several PBXs and startperformance and vulnerability testing.

- Provide support to the ADVANCED CLUSTER Munitions Program.

- Support the QUICKSTRIKE, MK 98 (MND), and AMNE programs in the 3area of Fuze/S&A development (PBXW-7).

FY90

- Complete vulnerability testing on HELLFIRE warheads, APOBS,and 16" gun submunition (cooperative programs).

- Support MK 50, 75mm, Follow-Through, ROCKEYE, and ADVANCEDCLUSTER programs.

- Establish additional transition efforts. iFY91-92

- Transition PBXW-121 to GP-bomb (ABF) program.

- Initiate transition efforts with the HARPOON and TOMAHAWKprogram offices.

- Continue support under previously established cooperativeefforts.

- Initiate transition efforts for new high performance (PBXW-119/120) and booster (PBXC-18/B-2188) explosives. I

11-30 iI

IUIIIIIII SECTION III* ORDNANCE

III

I

SECTION III

i PROJECT ELEMENT: ORDNANCE

COORDINATOR: Thomas E. Swierk, Code G22Naval Surface Warfare CenterDahlgren, VA 22448Phone: (703) 663-8716/AV 249-8716

INTRODUCTION: While new policies and technical requirementsrelated to insensitive munitions place much emphasis onincorporation of less sensitive energetic materials, that changealone does not always result in satisfying insensitive munitionsrequirements. Emerging technologies and mechanical designapproaches, which can be incorporated into warhead case and fuzeconfigurations, have been identified as candidates forinvestigation for providing improvements in insensitivity ofmunitions that cannot be achieved solely through changes inexplosives. This project provides for a broad demonstration ofSthese emerging technologies and design approaches to supportsurface and underwater ordnance systems which require IM fixes.

NAVY MISSION NEEDS: To successfully fulfill its mission, theNavy requires munitions that meet or exceed operationalperformance requirements while at the same time are notvulnerable to unplanned stimuli such as heat, shock or radiation.

STATUS OF TECHNOLOGY: Increasing emphasis has been placed onsafety related issues in ordnance design work in recent years.In addition to the newer, less vulnerable PBX explosiveformulations, concepts such as vented warhead cases and fuzeboosters have been incorporated into some of our newer weapons.New materials technology has been applied in all aspects ofordnance design including materials that offer increasedprotection from hazardous weapon performance is an ever presentdevelopment objective which often becomes an opposing objective

* to those safety issues such as insensitive munitions.

The development and adaptation of analytical models asefficient, easy-to-use design tools to assist the developer inthe assessment of their components with respect to theinsensitive munition requirement has long since been evolving.More work will continue in this area to particularly address thehazards unique to insensitive munitions. The use of newmaterials and material combinations has been and will continue tobe exploited in ordnance design. Materials applications willfocus both directly on the ordnance component and indirectly inthe application to shielding and/or container areas. Technologyrelative to initiation components has matured enough in recentyears to provide for many near term fixes for most weaponsystems. However, far term solutions will be more challenging todevelop as new weapon systems emerge.

i III-1

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APPROACH: Technology areas investigated under this taskelement will demonstrate new technology concepts in a widerange of generic hardware configurations and will alsoexploit the direct application of these concepts by Idemonstrating feasibility in weapon specific hardware.Generally, newer explosives with improved characteristicswill be utilized. Explosive selection for each technologyand/or weapon demonstration application will be based onrecommendations from the IMAD HE task element. Large scaletesting will be centered on demonstrating compliance withthe specific IM requirements such as fast/slow cook-off,bullet/ fragment impact and sympathetic detonation.Additionally, performance testing will be conducted asneeded to assess any performance impact of the new designconcepts.

The ultimate goal envisioned by the exploitation of the new 5technologies is to transition these new concepts into the Navy'sweapon systems. When the Navy's IM program was formulated in1984, fifty-three munition groups were prioritized by the CNOExecutive Board. This prioritization was updated in 1987.Technology will be aimed at providing solutions for ordnance-related IM demonstrations and ultimately transition opportunitiesfor deficiencies of these prioritized weapons. Severalapplications directly related to many of these weapon systemshave been identified for the various products identified for thistask element and are summarized in Figure 1. An example of a Itechnology transition schedule applicable to warhead conceptinvestigations is shown in Figure 2.

To accomplish the objectives of the IMAD program, the iordnance task element will:

a) Pursue warhead design concepts that depart from iconventional warhead design methodology by emphasizing IM-related technology. Primary emphasis will be placed onincorporating alternate materials or material combinationsto demonstrate improvements in shock and thermalcharacteristics without degradation in the performancecharacteristics.

b) Demonstrate the potential of advanced initiationconcepts for the use of extremely insensitive main chargeexplosives to solve the sympathetic detonation problems, iespecially for large warheads and bombs.

c) Utilize the broad technology base for armor andlightweight, high strength materials to identify optimummaterials for weapons systems applications includingpackaging and container applications. 3d) Demonstrate advanced fuze/initiation systems which willimprove upon munition insensitivity.

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U e) Establish and maintain a dialog with weapon offices tofacilitate the transition of new technology to specific

I applications.

PROJECT ELEMENT STRUCTURE: The project element has beenorganized into six primary task areas. Several subtasks havebeen identified for these task areas in which work may be pursuedindependently or in conjunction with companion subtasks. A listof task areas and subtasks and the performing activities for thisproject element is shown below:

3001 Program Coordination (NSWC)

1 3002 Warhead Design TechnologyA. Reactive Case Warheads (NSWC)B. Dual-explosive Warheads (NSWC)C. Armor-protected Warheads (NSWC)D. Composite Underwater Warheads (NSWC)E. Warhead Venting Concepts (NSWC)F. Stress Riser Concepts (NWC)G. Explosive Cook-off Pressure Confinement

Evaluation (NWC)

3003 Advanced Initiation TechnologyA. Radial Booster Concepts (NWC)B. Flyer Plate Concepts (NWC)C. Plane Wave & Bimodal Explosive Concepts (NSWC)

3004 Applied Materials & Shielding TechnologyA. Materials Research & Field Testing (NSWC)B. Fragment Hazard Methodology & Shielding

Concepts (NWC)C. Sympathetic Detonation Fragment

Characterization (NWC)

3005 Packaging & Container Technology5 A. Container Design & Fabrication (NWC/E)B. Container T&E (NSWC)

3006 Technology Transition / T&E SupportA. NSWC Weapon Program SupportB. NWC Weapon Program Support

PROJECT ELEMENT SCHEDULE: Detailed milestones associated withthe individual task areas are included in the sections thatfollow, however, significant milestones associated with theoverall project element are listed below:

FY89 - Conduct full scale testing of IMAD warhead designs andcooperatively demonstrate technology with weapon-specifichardware.

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Continue to investigate shock and thermal response potential Uof various reactive materials. Select explosives for the dual-explosive warhead concept, formulate warhead designs and screencandidates based on a performance comparison (test and analysis) Iagainst conventional single explosive warheads. Conduct largescale tests (bullet/fragment impact) of select dual-explosivewarheads. Formulate design options for passive armor protected mwarheads and screen candidates based on a performance comparison(test and analysis) against conventionally designed warheads. I

Composite case structures of varying material types andsizes will be fabricated with an integral honeycomb designand configured similar to existing underwater ordnance items.Hazard testing will be conducted to demonstrate improvedvulnerability characteristics. Cook-off mitigationtechniques which specifically address venting mechanisms thatutilize eutechtic materials will be investigated. Determine Sthe minimum pressure that insensitive PBX explosives can becontained at during cook-off without undergoing a transitionto detonation. 3

The existing modified MK 28 flying plate leads will first betested to determine plate velocities and plate break-upcharacteristics as functions of plate material, plate curvature,and driving explosive. Efforts will be initiated to optimize theinterfaces between insensitive boosters and main chargeexplosives and on flying plate axial boosters.

Several initiation techniques will be compared for theirability to properly initiate explosives that are insensitiveformulations with relatively large failure diameters.

Emphasis will be placed on providing specificrecommendations for barriers/shields/containers and documenting irecommended manufacturing procedures to convert the materials

into hardware items.

Evaluate DYNA2D, EPIC2, and MESA2D for handling modeling ofsympathetic detonation and fragment impact response.

Identify opportunities for technology transition, Icoordinating cooperative demonstration programs with weaponprogram offices. 3FY90-92 - Conduct full scale testing of technology concepts andconduct demonstrations of weapon ordnance items to supporttechnology transitions. Identify opportunities for technologytransition and coordinate cooperative demonstration programs with Iweapon program offices.

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i LONG RANGE PLANS (FY92-FY95): Since the IMAD program objectivesare geared toward complete transition to insensitive munitions byFY95, the near-term plans are directed toward having technologiesdemonstrated by FY92 so they can be qualified into weapon systemsby FY95. Completion of demonstrations prior to FY90 representsonly initial demonstrations. Long range plans include follow-oninvestigations, development, and demonstrations of alternatematerials and design concepts under the investigations currentlyplanned. Lower cost improvements will be demonstrated and usersupport will be provided. In addition, promising new approaches,yet to be identified, which can be engineered into systems thatare to enter the fleet after FY95, will be investigated.

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Task Title: Coordination and Technical DirectionTask Number: 3001Principal Investigator: Thomas E. Swierk, NSWC/D, Code G22, x8716

OBJECTIVE: Provide for sponsor liaison and overall coordination iof the objectives of the Ordnance Task Element and coordinatewith the other IMAD project elements.

BACKGROUND: The organization of the IMAD program by NAVSEAidentified NSWC to coordinate the element of the effort thatfocuses on IM technologies for all ordnance items (warheads andfuzes). Identification of this broad investigative area as amajor project element of the IMAD program necessitates having atask responsible for the management of a support organization andfor the coordination of and liaison with external activities.This task establishes a program office to provide for thatsupport.

APPROACH: Establish and maintain an administrative staff,technical support and program structure that will result intimely development and demonstration of promising technologies tomeet the IM requirements. Attend necessary meetings/conferences,coordinate technology exchange meetings/workshops, ensure thetransitions of new technology to weapon developers, prepare/present plans and/or reports and provide for other inputs Irequired by the sponsoring agencies.

PROGRESS: The task has resulted in coordination with NAVSEA,other DoD activities, contractors, and NSWC personnel throughmany informal meetings to support the objectives of the projectelement. Personnel were identified and committed to support allof the planned tasks of the project element. The annual budget Iwas closely monitored to ensure the timely execution of programtasks. The execution of this task also provided for program planupdates, progress reports and other planning/ reporting documents Ias required by NAVSEA. Restructuring of the IMAD program in FY88 required that this task element by reorganized, resourcesidentified and a new program plan written.

PLANS (FY89-FY91): Plans and major milestones of the task aredirected toward having IM technologies developed and demonstratedthrough the supporting investigative tasks in time to provide for Iengineering of these technologies into munitions in the FY91-95timeframe.

LONG RANGE PLANS (FY92-FY95): Long range plans include providing Utransition of demonstrated technologies into qualified munitionconfigurations to satisfy the FY95 goals. In addition, moreadvanced IM technologies will be identified. Demonstrations ofthese advanced technologies will be completed for use indevelopment of ordnance items for fleet introduction beyond FY95.

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Task Title: Warhead Design TechnologyTask Number: 3002Principal Investigators: Paul E. Bolt, NSWC/D, Code G22, x8716

David R. Crisp, NSWC/D, Code G22, x8716Katherine M. Ruben, NSWC/WO, Code U11, x1861Thomas J. Gill, NWC/CL, Code 3261, x7282Jack M. Pakulak, Jr., NWC/CL, Code 3262, x7262

OBJECTIVE: This task is subdivided into several subtasks whichaddress new and/or alternate warhead design ccncepts that couldlessen the susceptibility of various types of warheads to thewide range of IM threats which include fast/slow cook-off,bullet/fragment impact, and sympathetic detonation events.

BACKGROUND: The foundation of traditional warhead design hasbeen to offer the maximum lethality possible for weaponeffectiveness without sacrificing weapon system safety. IMinitiatives have added new dimensions to weapon system safety,thereby making the opposing performance and safety designcriteria that much more difficult to reconcile. Many of theestablished warhead design techniques may not be good enough topermit compliance with the IM requirements in the future. Novelideas and concepts must be examined as a means of achieving IMcompliance without sacrificing performance (i.e., overall weaponsystem effectiveness). When exploited judiciously, these newtechnologies may even yield both enhanced performance and safety1 characteristics.

APPROACH: Warhead design concepts that depart from conventionalwarhead design methodology by emphasizing IM-related technologywill be pursued. Primary emphasis will be placed onincorporating alternate materials or material combinations todemonstrate improvements in shock and thermal characteristicswithout degradation in the performance characteristics whencompared to conventional warhead designs. The basic approach forthe individual subtasks include the following:

I A. Reactive Case Warheads - Warheads which use reactivematerials as energy absorbing materials to help mitigate theeffects of shock-induced stimuli. Porous aluminum and otherlow density compositions will be evaluated as reactive/energy-absorbing components.

B. Dual-explosive Warheads - Warheads which utilize twoexplosives (layered) with significantly different output andvulnerability characteristics.

I C. Armor-protected Warheads - Warheads utilizing an outerlayer of an armor composite material, typically a ceramicwith a high strength, non-metallic encasement.

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D. Composite Underwater Warheads - Warheads which utilize acomposite/honeycomb case structure of varying thickness andmaterial composition. 3E. Warhead Venting Concepts - Techniques to vent thewarhead products of combustion during cook-off eventsutilizing various temperature sensitive materials within Iprefabricated vent ports.

F. Stress Riser Concepts - Techniques to vent the warhead 3products of combustion utilizing longitudinal stress risersto facilitate substantial case opening. Data will beobtained on the failure mode and related contributingfactors to the functioning of stress risers in genericwarheads. Evaluation of the predicted failures and actualtested failures will lead to the development of guidelinesby which stress risers may be designed.

G. Explosive Cook-off Pressure Confinement Evaluation -

Techniques to determine the critical confinement pressuresof insensitive explosives especially in the slow cook-offenvironment.

PROGRESS: Initial work with composite warhead designs was Iconducted in FY86-87. These warheads consisted of a filament-wound inner cylinder overlayed with a mat of preformed fragmentcubes and an outer cylinder which was also filament-wound. The Ibasic configuration was that of the NFTU. Three types of highstrength filaments (KRP, carbon, and S2 glass) and severalbonding techniques were chosen as the design variables. Limitedtesting demonstrated that warhead performance would not becompromised by employing this type of design approach. Testingwas conducted which also demonstrated that this type of warheadwas not vulnerable to the fragment impact threat. Other prior Iefforts pertinent to the planned subtasks include the following:

A. Reactive Case Warheads - Material source investigations 3and design support efforts were initiated and initialwarhead design concept studies were completed in FY 88.Generic test hardware (8-inch) was fabricated and largescale testing (fragment/bullet impact) was conducted withimproved vulnerability characteristics demonstrated.Concerns with scaling effects indicate a need to establish abetter understanding of the theoretical base (shock response iof the reactive materials). Sponsoring agencies and weaponoffices responsible for potential applications such asHarpoon and Tomahawk were briefed on the potential IMbenefits of this warhead concept.

B. Dual-explosive Warheads - Selection of an initialwarhead design (explosive combination and quantities) wasmade and hardware was fabricated and loaded in FY 88.

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Testing to be completed by the end of FY 88 included aperformance assessment with 8-inch warheads and5 vulnerability tests (fragment impact) with 11-inch warheads.

C. Armor-protected Warheads - Several preliminary designshave been completed. No hardware has been fabricated butheavy wall penetrator test units are available formodification if needed for future testing.

D. Composite Underwater Warheads - None, prior taskefforts did not address composite case structures forunderwater applications.

I E. Warhead Venting Concepts - None, new subtask.

F. Stress Riser Concepts - None, new subtask.

G. Explosive Cook-off Pressure Confinement Evaluation -None, new subtask.

PLANS (FY89-FY91): Plans and major milestones of the task byfiscal year are as follows:

i FY89

A. Reactive Case Warheads - Continue to investigate shockand thermal response potential of various materials in theexpanded materials data base. Conduct velocity predictionverification testing of advanced materials. Documentresults of prior large scale testing. Continue fragmentsize and multiple fragment effects studies.

B. Dual-explosive Warheads - Select explosives for thedual-explosive warhead concept, formulate warhead designsand screen candidates based on a performance comparison

(test and analysis) against conventional single explosivewarheads; conduct large scale tests (bullet/fragment impact)of select dual-explosive warheads.

C. Armor-protected Warheads - Formulate design options forpassive armor-protected warheads and screen candidates basedon a performance comparison (test and analysis) againstconventionally designed warheads.

D. Composite Underwater Warheads - Screening tests will beperformed on composite sandwich structures (panels orcylinders). Composite case structures of varying materialtypes and sizes will be fabricated with an integralhoneycomb design and configured similar to existingunderwater ordnance items. Hazard testing will be conductedto demonstrate improved vulnerability characteristics forshock and thermal stimuli.

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E. Warhead Venting Concepts - Cook-off mitigationtechniques which specifically address venting mechanismsthat utilize eutechtic materials will be investigated.Various types of materials, material quantities and vent Iport sizes will be considered. The generic underwater testunit will be used as the test vehicle.

F. Stress Riser Concepts - A small scale generic warheadwill be designed/fabricated and used as a test model. Thesewarheads will be fabricated using two different materials -a ductile steel and a relatively hard steel. Stress risersof various sizes and configurations will be cut into thetest items. A rupture due to internal pressure will bepredicted by standard equations and numerical methods. The1accuracy of the predictions will be determined by pressurizingthe test items until failure occurs. From these data,guidelines for sizing and placement of stress risers will be Ideveloped. The final part of this work will be to determinethe effects of stress risers on warhead performance.

G. Explosive Cook-off Pressure Confinement Evaluation- IThis task will determine the minimum pressure thatinsensitive PBX explosives, such as PBXN-!09, can becontained at during cook-off without undergoing a transition ato detonation. During FY88, a standard slow cook-off bombwas modified so that it would burst at any desired pressure.Selected PBX explosives will be cast into these bombs andtested through a range of burst pressures. The maximum safepressure for each of the explosives in slow cook-off willthus be determined. For those explosives which exhibitviolent reactions at unacceptably low levels of pressureconfinement, a follow-on effort will be initiated to attemptto identify liners and/or liner additives which can increasethe safe pressure confinement levels. Additionally, the Ieffects of outgassing agents in liners will be tested sincethese materials have been demonstrated to aid in thecontrolled rupture of warhead cases using stress risers.

FY90-91

A. Reactive Case Warheads - Complete fragment size andmultiple fragment effects studies and start designapplications of advanced reactive case warhead concepts.Conduct additional vulnerability testing as necessary todemonstrate concept suitability.

B. Dual-explosive Warheads - Complete all testing on thefirst two dual-explosive candidate configurations. Based onthe results of this test series, two to four additionalconfigurations will be formulated. Fabrication, loading,and a complete test series of at least one or two newconfigurations is planned.

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'II C. Armor-protected Warheads - Complete all tests of the

first two configurations. Generate up to three additionalcompromise configurations. Conduct complete IM testing onthe new candidate configurations. Complete specific designfor a warhead application.

I D. Composite Underwater Warheads - Several compositesandwich structures representative of underwater warheadcases will be built. Hazard tests to determine the degreeof improvement will continue. The standard for comparisonwill be existing data on current weapon systems. Analysisof test results may lead to design changes to improve weaponvulnerability characteristics. Additional hardwareincorporating similar features for tactical warheads may befabricated and tested.

E. Warhead Venting Concepts - Several warhead cases will bebuilt utilizing the various types of temperature sensitiveventing systems. Cook-off tests to determine the degree ofimprovement will continue. The standard for comparison willbe existing data on current weapon systems. Additionalhardware incorporating similar features for tactical

i warheads may be fabricated and tested.

F. Stress Riser Concepts - Technology investigations begunin FY89 will continue to completion as the merits of thisconcept should be demonstrated and available for transitionto specific weapon applications.

G. Explosive Cook-off Pressure Confinement Evaluation -Technology investigations begun in FY89 will continue tocompletion as the merits of this concept should bedemonstrated and available for transition to specific weaponapplications.

LONG RANGE PLANS (FY92-FY95): Long range plans include providingsupport to expedite the transition of innovative technology intothe Navy's warheads for fleet munitions. In addition, new andmore advanced warhead concepts will be investigated fordemonstrations, as appropriate, for munitions planned forintroduction beyond FY95.

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Task Title: Advanced Initiation Technology ITask Number: 3003Principal Investigators: Dr. C.D. Lind, NWC/CL, Code 3262, x7528

Joseph Etoch, NWC/CL, Code 3356, x7611 IRobert Moffett, NSWC/WO, Code R12, x2029

OBJECTIVE: This task is divided into four subtasks with thefollowing objectives:

A. Radial Booster Concepts - Develop, demonstrate, and 3optimize radial output booster technology for application toall new fuze designs with possible application to currentfuzes with marginal reliability or for boosters which must muse more insensitive materials.

B. Flyer Plate Concepts - Develop, demonstrate, and ioptimize flying plate lead technology for application to allnew fuze designs with possible application to current fuzeswith marqinal reliability or for boosters which must usemore insensitive materials.

C. Plane Wave & Bimodal Explosive Concepts - Evaluatevarious boostering techniques to determine the most Iefficient method to initiate insensitive explosives.Initial emphasis will be centered on plane wave and bimodalexplosive techniques and slapper initiation technology.Other technology areas such as multi-point initiationsystems and implosion techniques will also be pursued.

BACKGROUND: IM technology is being developed to reduce the Isusceptibility of ordnance to fast/slow cook-off, bullet/fragment impact and sympathetic detonation. Advanced initiationconcepts will be required for the use of extremely insensitive Imain charge explosives to solve the sympathetic detonationproblems, especially for large warheads and bombs. Radial outputboosters have particular application to Phoenix, Sparrow, Shrike,and Standard Missile. Flying plate boosters would be especiallyuseful for AMRAAM, Harpoon, Tomahawk, Maverick, and GP Bombs.Other initiation concepts will also have widespread applicationto a variety of weapon systems.

APPROACH: 3A. Radial Booster Concepts - Initial efforts willconcentrate on radial output booster designs. Units will befabricated, loaded and tested against main charge explosiveswhich are especially difficult to reliably initiate. Theboosters will be designed to be compatible with the flyingplate leads being developed under a companion subtask.Testing will be conducted to complete the evaluation of MK I28 flying plate leads.

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B. Flyer Plate Concepts - Candidate designs will beoptimized through a series of tests to evaluate the majordesign parameters of plate material, thickness, radius ofcurvature, diameter and type of explosive.

C. Plane Wave & Bimodal Explosive Concepts - Evaluate theability of various boostering techniques to properlyinitiate current and representations of future insensitiveexplosives. Computationally compare the ability of the bestboostering techniques to optimize design variables.

PROGRESS:

A. Radial Booster Concepts - Modified MK 28 flying plateleads were obtained. The modifications included usingstainless steel in place of aluminum and testing threedifferent plate curvatures. These leads were loaded withPBXW-7, HNS, and CH-6 explosives. A preliminary design wasmade for a radial output booster.

B. Flyer Plate Concepts - Initial efforts concentrated onthe MK 8 size lead because it would fit within a bomb fuzebooster. Five flying plate materials were tested againstseveral booster explosives using vented booster hardware.These tests were unsuccessful because the MK 8 lead provedto be too small to reliably function.

C. Plane Wave & Bimodal Explosive Concepts - None, newsubtask.

PLANS (FY89-FY91): Plans and major milestones of the task byfiscal year are as follows:

FY89 A. Radial Booster Concepts - The existing modified MK 28flying plate leads will first be tested to determine platevelocities and plate break-up characteristics as functionsof plate material, plate curvature, and driving explosive.The best combinations will then be tested using actualboosters. This work will be coordinated with other subtasksand with the GP Bomb program to develop insensitive fuzeboosters. Efforts will be initiated to optimize theinterfaces between insensitive boosters and main chargeexplosives and on flying plate axial boosters.

B. Flyer Plate Concepts - Hardware will be fabricated andtested using high speed photography and other instrumentationto evaluate performance of the leads as functions of severalparameters. The best design(s) will then be tested todetermine their ability to reliably initiate a variety ofinsensitive booster explosives. This work will becoordinated with the GP Bomb program to develop insensitivefuze boosters.

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C. Plane Wave & Bimodal Explosive Concepts - To developthe required data, several initiation techniques will becompared for their ability to properly initiate explosivessuch as PBXN-103, PBXW-115, and PBXW-121. The selectedexplosives are current, insensitive formulations withrelatively large failure diameters which are representativeof future (developmental) insensitive explosives. Inaddition to the experimental tests, computational methodswill be used to help optimize the boostering techniques,especially those that show the most promise.

FY90-91A. Radial Booster Concepts - Technology investigationsbegun in FY89 will continue to completion as the merits ofthis initiation concept should be demonstrated andavailable for transition to specific weapon applications.

B. Flyer Plate Concepts - Technology investigations begunin FY89 will continue to completion as the merits of thisinitiation concept should be demonstrated and available fortransition to specific weapon applications.

C. Plane Wave & Bimodal Explosive Concepts - Technologyinvestigations begun in FY89 will continue to completion asthe merits of these various concepts should be demonstratedand available for transition to specific weaponapplications.

LONG RANGE PLANS (FY92-FY95): Long range plans include providingsupport to expedite the transition of advanced fuze and/orinitiation technologies into fleet munitions. In addition, newand more advanced IM initiation technologies will be investigatedfor demonstrations, as appropriate, for munitions planned forintroduction beyond FY95.

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ITask Title: Applied Materials & Shielding TechnologyTask Number: 3004Principal Investigators: Dr. Benjamin D. Smith, NSWC/D, Code R35, x8901

Martha Wagenhals, NWC/CL, Code 3894, x2206Eric Lundstrom, NWC/CL, Code 3894, x2206

OBJECTIVE: This task is divided into three subtasks with thefollowing objectives:

A. Materials Research & Field Testing - Incorporateadvanced materials into the design of weapon systemcomponents, including but not limited to warheads, warheadshrouds and/or protective shields, and shipping/stowagecontainers for the purpose of minimizing thermal and shockresponses in events such as cook-offs and fragment/bulletimpacts, while maintaining high levels of operationalperformance.

B. Fragment Hazard Methodology & Shielding Concepts -Develop a methodology which can be used by the designcommunity to estimate which portion of the fragment hazardspectrum and associated shock hazard to which their weapon isvulnerable, compare the areas of vulnerability with theiranticipated fragment/shock environment to determine if theyneed additional protection to prevent inadvertent initiationof their weapon, and to provide a means of estimating thedegree of protection required.

C. Sympathetic Detonation Fragment Characterization -Develop a design methodology for specifying energeticmaterial sensitivity requirements to enable munitions tosurvive the hazards associated with the sympatheticdetonation environment.

BACKGROUND: The insensitivity of munitions can be improved bythe use of new, lightweight, high strength, thermal and shockresistant materials. These materials may serve many purposes inweapon design. Weapon systems will often incorporate severaldifferent materials in varying thickness and configurations. Theoptimum selection of each material type, thickness andconfiguration for a variety of applications as well asidentifying material sources and fabrication/assembly methodologyare all critical considerations and will be incorporated intoweapon design guidelines. The large number of warheads willrequire a variety of materials and configurations to address boththe IM and performance characteristics. A combination ofjudicious material selection and munition/container design isrequired to fully demonstrate the potential for IM improvementsin armored and lightweight munition design. An integratedsystems engineering approach is required.

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APPROACH:

A. Materials Research & Field Testing - The broadtechnology base for lightweight, high strength materials 5forms a sound foundation for the application of thesematerials to numerous weapon systems. Materialcharacterizations coupled with laboratory and field testing Iare designed to develop a material data base from which thebest material of construction and/or protective materials(i.e., barriers, shields) can be integrated into specificdesigns. This subtask provides the material characteristicsdata, the level of protection that can be achieved againstthe various threats, and acceptable manufacturing proceduresto weapon system designers and manufacturers.

B. Fragment Hazard Methodology & Shielding Concepts - Theframework for the materials/shielding methodology exists. IThere are four parts to the methodology and include:

1) producing a fragment environment definition by developinga "threat map" for each specific fragment source;2) determining the detonation sensitivity of each componentof the weapon to predict vulnerable regimes which involvedeveloping hazard plots for each weapon component containingan energetic material; 3) quantifying the predictions bydetermining the probability of being hit by detonationcausing fragments; and 4) establishing a data base ofshielding material properties to analytically estimate which Imaterial and material thickness, or combination of materials,is required to slow down and break up the hazardousfragments, and to provide an estimate of the degree of riskassociated with each suggested level of protection. Thisrequires characterization of armor materials to provideequation-of-state data. Ballistic characterization testsand computer modeling of results is needed on an iterativebasis to develop the model for the materials and a similartest/model scenario is needed for developing an improvedmodel for the penetration mechanics of armor materials and Itheir ability to degrade the effects of the hazardousfragments.

C. Sympathetic Detonation Fragment Characterization - lDetermine the shapes and sizes of fragments at the close-to-origin distances occurring during sympathetic detonationevents. I

PROGRESS:

A. Materials Research & Field Testing - Efforts during FY I86-88 identified a variety of structural materials and armormaterials. A number of tests were conducted to more fullycharacterize these materials with respect to aiding in thecompliance with the IM requirement. A systems approach was

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initiated to fully integrate these materials into warheadcase design concepts and protective hardware such asshipping containers, barriers and shrouds. Specificaccomplishments include identifying fabrication procedures,conducting gas gun tests, fragment simulator projectiletests, fragment impact tests (FI), and sympathetic detonationtests. A number of specific weapon system applications havebeen investigated. A major effort has been to interfacewith other weapon system project offices to apply thematerials technology to all weapon systems currently in thefleet or planned to be deployed in the near future.

B. Fragment Hazard Methodology & Shielding Concepts - Allelements of the hazard methodology - - in place but requiresubstantial amplification and valid on. Characterizationdata on nine munitions are in the computer data base. Thebasic elements for preparing threat maps and hazard plotsare in place. Several different penetration/responsecomputer programs are being used and evaluated for theirapplicability to this methodology. Methods to account forvarious real world factors have been investigated andpartially implemented. Sympathetic detonation analyses arebeing conducted for weapon program offices based on thismethodology.

C. Sympathetic Detonation Fragment Characterization- None,3 new subtask.

PLANS (FY89-FY91): Plans and major milestones of this task by3 fiscal year are as follows:

FY89

3 A. Materials Research & Field Testing - Emphasis will beplaced on providing specific recommendations for barriers/shields/containers and documenting recommended manufacturingprocedures to convert the materials into hardware items.Specific areas will include: a) improving the performanceof ceramics used as curved-surface tiles by selecting basematerials of higher purity, packing density and hardness;b) fabrication of cylindrical-shaped KRP or S-2 glass GRP toserve as the inner protective barrier (nearest theexplosive); c) incorporation of other non-metallic shock-absorbing materials and documentation of the fabricationprocedures using sheet and granular forms; 4) providesupport to warhead design related subtasks as requested.

i B. Fragment Hazard Methodology & Shielding Concepts - Addother warhead characterizations to the data base andautomate the preparation of threat maps basing them onfragment data bases. Set up the methodology for generationof hazard plots and document. Evaluate DYNA2D, EPIC2, and

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MESA2D for handling modeling of sympathetic detonation andfragment impact response. Establish test procedures,conduct tests and model the results. Develop fragment/warhead scale models for testing of energetic material aresponse to fragment impact for proof-of-concept testing.Conduct scale model proof-of-shielding-concept sympatheticdetonation tests. Model/verify small scale test results and Icomplete computer methodologies.

C. Sympathetic Detonation Fragment Characterization -Generic naturally fragmenting and/or heavy wall penetrator Iwarheads will be statically detonated; and specially modifiedx-ray techniques used to observe fragment formation, shapes,sizes, velocities, and orientations. If it is determinedthat the fragments at typical warhead-to-warhead stowageseparation distances are significantly different(physically) than at the longer characterized distances, Ithen work will be proposed to model and test the effectsthese near field fragments have on the sympatheticdetonation of warheads and bombs. 3

FY90-91

A. Materials Research & Field Testing - Continue prior Iefforts with emphasis on the evaluation of thermoplasticmaterials in combination with the established armormaterials. It is anticipated that better performing 3ceramics will become available either because of improvedfabrication procedures or a blending of ingredients toimprove the material properties. 3B. Fragment Hazard Methodology & Shielding Concepts -Validate the methodology and selected shielding concepts forfull scale (in containers) sympathetic detonation testing Iand document results.

C. Sympathetic Detonation Fragment Characterization - None. 3LONG RANGE PLANS (FY92-FY95): Long range plans include providingfor any support necessary to expedite the transition of high-strength, lightweight structural and armor materials into Navy Imunitions designs or shielding concepts. In addition, new andmore advanced materials and their associated fabricationmethodology will be investigated for demonstration, as Iappropriate, for munitions planned for introduction beyond FY95.

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Task Title: Packaging & Container TechnologyTask Number: 3005Principal Investigators: S. Petoia, NWS/E, Code 8021, x2840

C. Han, NWC/E, Code 8021, x2843D. MacLeod, NWS/E, Code 8021, x2841

OBJECTIVE: Investigate and provide packaging and/or containeralternatives which will reduce the vulnerability of Navymunitions when subjected to unplanned stimuli resulting fromfire, shock, fragment or bullet impact, electrostatic dischargeor electromagnetic radiation.

l BACKGROUND: For a number of munitions it will be difficult, ifnot impossible, to fully comply with the IM requirements throughincorporation of less sensitive explosives, mitigation devices,or redesign within the specified timeframe (especially for thefragment impact and sympathetic detonation threats). Theredesign of packaging and/or container items may solve or3 alleviate some of the remaining problems.

APPROACH: Investigate the effectiveness of current packaging toprotect munitions from unplanned stimuli by conductingperformance testing and evaluating the results. Where shortfallsexist, develop and validate alternatives that provide therequired degree of protection. Recommendations will be provided3 to the weapon program managers.

PROGRESS: This task has been narrowed to the investigation ofprotection against the bullet impact, fragment impact andsympathetic detonation threats without adverse effects to thetransportation, handling and storage functions. The munitionswith known problems have been prioritized and efforts have begunto address these weapons. A generic container has been designedfor testing new concepts in munition protection. Mathematicalmodeling is planned for the evaluation of protective materials5 for these new containers.

Additionally, the following items have been accomplished:prioritized weapons into appropriate categories based on thelevel of vulnerability against the broad IM threat spectrum, metwith industry representatives to explore new barrier/dunnagematerials, provided extruded sidewall specimens to NSWC fortesting to establish baseline bullet/fragment impact data onmaterials used for container designs, conducted limited slowcook-off testing on a typical steel container to establishbaseline thermal data, coordinated a thermal study at NSWC tosimulate fast cook-off of a containerized weapon, and assisted inthe preparation of proposals for the development of newg containers which improve the resistance against the IM threats.

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PLANS (FY89-FY92): Plans and major milestones of this task by 1fiscal year are as follows:

FY89 IReview and evaluate new/improved barrier and dunnagematerials for packaging, design and fabricated genericcontainers for demonstration tests, prepare IM test plans/procedures for container evaluations/demonstrations, conductfield tests at NSWC to demonstrate IM improvements withrespect to containers/container materials, continue work onthe needs addressed in the prioritization of munitions forthis task, coordinate with program managers on specific IMcontainer requirements, monitor IM hazard tests ofcontainerized weapons, and provide assistance to weaponmanagers in the preparation of IM proposals/POAMs forcontainers and/ or packaging.

FY90-92

Continue work on the needs addressed in the prioritization Uof munition containers for the packaging/container task andincorporate "lessons learned" into Navy packaging/containerdesign requirements such as a MIL-SPEC/STD document.

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l Task Title: Technology Transition/T&E SupportTask Number: 3006Principal Investigators: William H. Grigsby, NSWC/D, Code G22, x8716

John Fontenot, NWC/CL, Code 3208, x7234

OBJECTIVE: Exploit opportunities to transition new IMtechnologies as appropriate to Navy weapons. Additionally,provide support to principal investigators, as needed, for their

T&E programs.

BACKGROUND: Many instances will arise when both the IMAD andweapon programs can mutually benefit from joint test programs.Typical instances will include performing demonstratior- of IMADconcepts in weapon system ordnance sections and assisting weaponoffices in planning technology transitions. It may also bedesirable to have one program or the other collect additional orspecialized data in tests planned for other purposes.

APPROACH: Establish and maintain a dialog with weapon offices tofacilitate the transition of a new technology to specificapplications. Assist potential customers (weapon developers/program offices) in planning cooperative programs to demonstrateIM technology advancements that would apply to specific weapons.These efforts would often be mutually beneficial - significanttechnical data would be obtained for the IMAD program and IMsolutions would be identified/demonstrated for the weapon systemto solve an IM deficiency. This task will also provide supportto other principal investigators by coordinating hardwarefabrication, explosive loading and test scheduling, as requested.

I PROGRESS: The technology transition efforts have continued atboth NSWC and NWC with initial contacts made with personnelassociated with the following programs: Standard Missile,Vertical Launch System, SMAW, Advanced Sea Mine, MineNeutralization System, 16"/50 gun ammunition, Harpoon, Tomahawk,HARM, Sparrow, Phoenix, AMRAAM, GP bombs, Maverick, Smokeye,Walleye and the Advanced Cluster Munition. It is anticipatedthat many other programs will share in this technology program inthe future. Technical advances put forth by the above taskelements should materialize into transition demonstrations orprograms coordinated through this task element.

PLANS (FY89-FY92): Future plans of this task includecontinuing efforts to identify opportunities for technologytransition and to coordinate cooperative demonstration programswith weapon program offices.

I LONG RANGE PLANS (FY93-FY95): Long range plans include providingtransition of demonstrated technologies into qualified munitionconfigurations to satisfy the FY95 goals. In addition, moreadvanced IM technologies will be identified. Deronstrations ofthese advanced technologies will be completed for use indevelopment of ordnance items for fleet introduction beyond FY95.

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IIIIIII5 SECTION IV

I PROPELLANTS/PROPULSION

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U SECTION IV

P ROJECT ELEMENT: PROPELLANTS/PROPULSION

COORDINATOR: Andrew C. Victor, Code 32051Naval Weapons Center, China Lake, CATEL: (619) 939-7391/AV 437-7391

INTRODUCTION: The propellant in missile rocket motors and in gunammunition constitutes up to 80% of the explosive material in themunition. To meet the Navy's requirements for insensitivemunitions (IM), we must ensure that safety hazards of thepropulsion units of our munitions are reduced to levelscompatible with NAVSEAINST 8010.5A, Technical Requirements forInsensitive Munitions. Because the requirements of thisinstruction were not a major factor in the design and developmentof propulsion units until 1985, there is no mature technology basefrom which to draw the improvements required.

The past focus of exploratory development programs in tacticalrocket propulsion has tended to be oriented toward improvedperformance rather than toward reduced sensitivity. Oneexception to this has been the de facto requirement thatpropellants used in Navy rocket motors, particularly air-launchedrocket motors, meet requirements for Class 1.3 explosives. Othernotable exceptions have been the Navy's and the Army's work onLow Vulnerability Ammunition (LOVA) propellants for gunpropulsion and the Navy's 6.2 and 6.3A programs on reducing the3 output violence of munitions in response to fast cook-off.

The past focus of research programs in propulsion, while alsooriented toward improved performance, has had to considersensitivity as a result of more and more energetic ingredientsinvolved. As a result of that work, some promising newingredients for advanced propellants are available.

Through the Navy's work on strategic propellants and explosives,we have considerable techniques and expertise that can be appliedto the sensitivity problems of tactical propulsion. However, wehave learned through the IMAD program that tactical propellantspresent additional unique sensitivity problems.

3 NAVY MISSION NEEDS: The propulsion units needed to meet Navymissions are defined in terms of threats (targets), major capitalassets (ships and aircraft), and the performance capabilities ofother parts of the munition delivery system (warhead, guidance,etc.). Propulsion units are required to deliver the munitionwithin a certain distance of the target, within a certain time,and sometimes, with reduced detectability, and by trajectory andvelocity selected to maximize survival of the munition and

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capital assets. Meeting these mission needs has required all theenergy that modern chemical science and engineering can packageinto the limited volume available in modern propulsion units. 5Even though care has generally (especially recently) been takento avoid propellants that are obviously detonable in munitions,unacceptably violent reactions by rocket motors have beenobserved in response to many of the IM stimuli.

Meeting the Navy's mission needs will require propulsion units 3capable of current performance levels now, and improvedperformance levels in the future. At the same time, these unitsmust meet the requirements for insensitive munitions. To meetthese needs, this project addresses all Navy tactical rocket, Imissile, and gun propellant systems.

STATUS OF TECHNOLOGY: The success of rocket propulsion 3technology in meeting its key objectives has resulted in itfrequently being called "a mature technology." This appellation,however, should be qualified by a careful look at the limitedrequirements that have been put on that technology, and at themany uncertain factors added by the requirement for insensitivemunitions. First of all, whenever fuel and oxidizer are packagedtogether, as they are in a rocket or gun propellant, you have anexplosive. While the terms "propellant" and "explosive," areused synonymously in the following text, it should be understoodthat we are always referring to propellants, but emphasizing one Uor the other aspect of their behavior.

All propellants (explosives) have some degree of sensitivity.When initiated, all propellants (explosives) react with some ilevel of violence. That is always true. The InsensitiveMunitions Program sets a practical target level for minimizingthe sensitivity and reaction violence of the propellants used. IPropulsion performance is maximized by maximizing the energydelivered by the propellant. Fortunately, sensitivity andexplosive violence are not strictly monotonic functions of the Ipropellant energy. However, for some of the propellants studiedmost recently in research and exploratory development, the hazardbehavior is, unfortunately, directly related to energy content.Under exploratory development programs recently started by theNavy, and also some ongoing abroad, other approaches toachieving high delivered propellant energy with reducedsensitivity and reaction violence are being tried.

The other side of sensitivity and reaction violence involvespressure buildup in a reacting explosive. If an explosive isconfined, internal pressure can increase without relief. A chainof events may progress that ultimately leads to a very violentexplosion or detonation. The time required for this progressionand its ultimate violence depend on the stimulus, the explosive,and the degree of confinement.

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Successful reduction of the violence of munition reactions infuel fires (fast cook-off) demonstrated by NAVAIR's Weapon FastCook-off Program (which has subsequently become the NAVAIR IMTechnology Transition Program) has depended on reducingconfinement (venting of the case) of the explosive prior toignition. In this way it has been possible to modify warheadsand rocket motors that exploded or detonated in fast cook-off sothat the maximum reaction was only burning. A number of conceptsfor actively reducing case confinement have been demonstrated bythe NAVAIR program. More recently many additional concepts havebeen demonstrated by the IMAD program. We have recentlydemonstrated that slow cook-off reaction violence can also bedecreased by venting in some systems. More active interventionfor slow cook-off relief, if needed for some explosives, mayrequire ignicion of the explosive after venting but prior toexponential self-heating. The IMAD Propulsion Project hascompleted feasibility and proof-of-concept tests on a multihazardmitigation system which successfully vented rocket motor cases infast cook-off, slow cook-off, and bullet impact tests. IMADefforts on active mitigation systems for rocket motors hasterminated at this point. It is not feasible to develop ageneric mitigation system since such systems must be tailored tothe specific motor they are designed to be used on. It makesmore sense to work with a specific weapon system, if an activemitigation system is needed. We believe that such a system,since it is intrusive to a rocket motor's primary function shouldbe incorporated only as a last resort.

There is a regime of heating between the current fast cook-offand slow cook-off test conditions which is quite likely to occurin hazard scenarios. This intermediate cook-off regime, whichcauses extreme reaction violence similar to that experienced inslow cook-off, is now being studied in the IMAD program todetermine its range of applicability, its effect on reactionviolence, and methods for mitigating i s effects. Tests of

rocket motor reaction violence at a 75 /hr (intermediate) heatingrate have been Berformed to compare the results with thoseobtained at a 6 hr heating rate for rocket motors that detonatedat the slower heating rate. The results indicate that reaction3 violence is greatly reduced at the higher heating rate.

One category of propulsion technology available derives itsinsensitivity from separation of fuel and oxidizer. On the IMADProgram we refer to such technology as "Alternate PropulsionSystems." Bipropellant gels, liquids, solids, and hybrids aswell as airbreathing systems (ramjets, ducted rockets, andturbojets) comprise this category. The IMAD Program is studyingthe potential of alternate propulsion technology to meet Navymissile propulsion performance requirements. We are also engagedin testing that technology available from previous exploratorydevelopment. A bipropellant gel system developed by the Army(MICOM), TRW, and Talley was readied for IM large-scale hazardtests during FY88.

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Preliminary work on several new rocket motor case concepts (strip

laminate, composites, and hybrids) shows promise for passiveventing in response to hazardous stimuli. Some designs of thesecases vent well and quickly in fires and in response to bulletand fragment impact, and some have the potential to relieve theviolence of response to intermediate and even slow cook-offsituations as well.

IM vulnerability testing of low vulnerability ammunition (LOVA)propellants for Navy 76 mm and 5"/54 guns was completed during iFY87. Final reports of all the tests were completed in FY88.Effort to develop insensitive primers, started in FY87, had to bestopped during FY88 because of a major budget cut. Theseinsensitive primers are needed to get the full benefit of theimproved insensitivity provided by LOVA propellants.

At this stage in the IMAD Program, it is not absolutely clearwhat the relationships between stimulus, explosive, andconfinement are for the wide range of these three variables inour existing rocket motors. Clarification of this relationship,while at the same time developing satisfactory technology forhazard reduction, are critical goals of this project. As aresult of data obtained from large scale tests on generic motorsand small scale tests on propellants during the past year we haveidentified prioritized goals for insensitive propellants for Navymissiles and have prepared test procedures for testing thosepropellants prior to scale-up of these formulations and loading nof generic motors.

The ultimate goal for exploitation of the new technologies is totransform these new concepts into the Navy's weapon systems.Several applications directly related to many of these weaponsystems have been identified for the various products identifiedfor this task element and are summarized in Figure IV-l.

APPROACH: The work of this project is focused on reducing thesensitivity and hazardous output of rocket motors and gun mpropulsion systems in the Fleet. Collection of available hazarddata on rocket motors currently in the Fleet has been started.However, not all necessary data exist, and because existing dataare not adequate, we must assemble a data base of the responses Iof current rocket motors to the thermal and shock stimulispecified in the Navy's technical requirements for insensitivemunitions. To establish a consistent data base (baseline) we Iare performing large scale hazard tests of conventional (in use)propellants in generic rocket motors.

The project maintains an intimate link with the weapon programofficer responsible for fleet missile propulsion. In this way wehave been able to directly support specific weapon IM plans anddevelopment including Harpoon, Sidewiner, Standard Missile,HARM, Hellfire, Skipper (Shrike), Tomahawi: and VLS systems. The

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link with the weapon offices feeds back into the IMAD propulsion 3project and focuses IMAD technology development on to real fleetrelated problem areas. In the past, rocket motor cases have beendesigned for performance only. Those case concepts, such asstrip laminate and composite cases, which have demonstratedreduced reaction violence in some vulnerability tests, have beena bonus. Other case :oncepts are being investigated under this 1project. These include the concept of a case "tuned" toattenuate the shock energy transfer upon fragment impact, whilestill offering the cook-off and bullet impact advantages of striplaminate and composite cases. Another concept being investigatedinvolves design of composite cases to enhance crack propagationupon bullet or fragment impact while retaining necessaryintegrity under all other conditions.

The key function of mitigation concepts, as they are envisionedtoday, is to relieve confinement of energetic material in a Imunition case. This may be accomplished either passively, aswith strip laminate or composite motor cases, or actively, aswith linear shaped charge or thermite case penetrator concepts.In either method a three step process occurs: 1) the stimulus is Isensed, 2) a signal to vent the case is sent, and 3) the case isvented. With active mitigation concepts, it is necessary todesign components to specifically perform each of these three 1steps. The primary utility of active mitigation concepts, as wehave addressed them, is to provide a retrofitable means to enableexisting rocket motors to meet IM requirements prior to a timewhen advanced propellant and case technology can be used in newproduction. Other key functions and steps for passive mitigationconcepts are beginning to emerge from our work. One of these isbased on using the mitigation concept to change the stimulus assensed by the energetic material and thus reduce the sensitivityof the munition as a whole. Development of case opening devicesunder this project has been completed. Development of sensorshas ceased. Mitigation concepts based on shielding in containerand stowage space designs are supported by other IMAD projectsand will be coupled with propulsion IM requirements as part ofthe technology transition and weapon system integration efforts.

Propellants, the energetic materials in rocket motors, areultimately responsible for hazardous behavior. The propellant(s)in any rocket motor must meet both performance requirements andinsensitivity requirements for probable scenarios. 1

Those propellants that meet established insensitivity standardsin small scale tests, and offer future improvements in bothperformance and insensitivity, will be scaled up for productionof quantities large enough for motor loading. Thet will beloaded into generic rocket motor cases for large scalevulnerability testing in accordance with the insensitivemunitions technical requirements. Several candidate propellants Iare currently being developed under this project as well as under

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the Navy's 6.2 Propulsion Program. In addition, a considerableamount of new commercial "insensitive" propellant development hasrecently started to help meet the Navy's requirements. Inresponse to our FY88 Broad Area Announcement in the CommerceBusiness Daily, we received 12 proposals for insensitivepropellant development. As many as possible (after funding cuts)were supported during FY88. We intend to fund additional work inthe future.

When the results of the small and large scale tests arecorrelated, they provide a means for projecting the behavior ofmunitions from small scale tests results. This is a basis foruseful heuristic rules that provide guidance for propellantselection and for the design and development of mitigationconcepts. The progress we have already made along these lines isbeing avidly welcomed by the technical community and incorporatedinto the work of other services and allied nations.

LOVA propellants, while demonstrated under this program to reducethe sensitivity of gun propelling charges, must be furtherprotected with less sensitive primers and with venting cases.These were the thrusts of the task before being stopped due to3 funding cuts.

Advanced case technology offers a way to achieve reduced outputin response to fast cook-off and bullet impact threats. There isalso some potential that slow and intermediate cook-off violencecan be reduced by using advanced cases. For example, we havedemonstrated reduction of violence for one propellant fromdetonation to deflagration in slow cook-off by using a compositecase. Technology developments will provide cases capable ofreducing the shock stimulus to the propellant grain, thusattenuating the fragment impact and sympathetic detonationthreat.

PROJECT STRUCTURE: The IMAD propulsion project is organized into* the six tasks shown in Table II.

The Naval Weapons Center, China Lake (NWC) is the lead laboratoryfor this project. The project is implemented by the Navy R&DCenters with expertise in propulsion technology and relatedhazard behavior. Additional support is obtained from appropriatecontractors and other Government laboratories. The projectbuilds upon the results of the Navy's exploratory development(6.2) programs in missile and gun propulsion. Close couplingwith other propulsion development programs, including industrialR&D, other service programs, and other national programs ismaintained.

PROJECT SCHEDULE: Significant milestones associated with theproject are listed below:

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IFY89 I

-Continue case development and acquisition.-Complete large scale vulnerability tests of existing Navypropellants. i

-Complete IM hazard tests on bipropellant gel alternatepropulsion system.

-Start investigation of other alternate propulsion systems.-Start small scale tests of other service and industrypropellants, new propellants with advanced ingredients, andother propellant advances.

-Load developmental Navy propellants into generic cases andstart large scale vulnerability tests.

-Begin loading of viable other service and industrypropellants into generic cases for large scalevulnerability tests.-Continue small scale tests of developmental propellants.-Continue advanced development (scale-up and test) of Iselected developmental propellants.

-Continue funding of industrial IM propellant development.-Expand large scale vulnerability test program to includeadvanced case concepts. I-Continue to improve prediction methodology.-Continue development, acquisition, and test of motor casesbased on new design methodology.-Identify critical variables for "IM propellantqualification" from results of this project and adjust testprotocol and procedures accordingly.-Complete intermediate cook-off investigation.-Start development of alternate propulsion concepts with IMpotential.

-Publish and promulgate results of the project in a timelymanner.-Update data base for IM propulsion/propellants.-Support weapon systems IM programs. I-Evaluate VLS IM threat environment.

FY90-Support transition of demonstrated technologies to weapons.-Continue large scale vulnerability tests of developmentalpropellants.

-Continue small scale tests and evaluation of newly emergingpropellants.

-Continue funding of industrial IM propellant development.-Continue advanced development (scale-up and test) of Iselected developmental/advanced propellants, includingindustry.

-Continue test and evaluation of alternate propulsionconcepts. I-Qualify propellants and propulsion systems for use inmissiles.-Continue and accelerate acquisition and test of motor casesbased on new design methodology.-Continue to improve prediction methodology.

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-Publish and promulgate results of the project in a timelymanner.-Maintain data base for IM propulsion/propellants.-Support weapon systems IM programs.-Document results and recommendations based on the program.

FY91-Support transition of demonstrated technologies to weapons.-Continue large scale vulnerability tests of developmentalpropellants.

-Continue small scale tests and evaluation of newly emergingpropellants.-Continue funding of industrial IM propellant development.-Continue advanced development (scale-up and test) ofselected advanced propellants, including industry.-Complete testing of alternate propulsion concepts andselect primary concept for development and performancedemonstration.-Qualify propellants and propulsion systems for use inmissiles.-Support tests of advanced motor cases based on new designmethodology in munition configurations.-Maintain data base for IM propulsion/propellants.-Support weapon systems IM programs in transition toproduction modifications.

FY92-Support transition of demonstrated technologies to weapons.-Continue large scale vulnerability tests of advancedpropellants.

-Continue small scale tests and evaluation of newly emergingpropellants.

-Continue advanced development (scale-up and test) ofselected advanced propellants, including industry.-Support tests of advanced motor cases based on new designmethodology in munition configurations.-Qualify p-opellants and propulsion systems for use inmissiles.-Maintain data base for IM propulsion/propellants.-Support weapon systems IM programs in transition toproduction modifications.

-Document results and recommendations based on the program.

LONG-RANGE PLANS (BEYOND FY92): Table I shows predicted progressof technology development and demonstration in this project. Thenumbers in the table represent fiscal years for transitionwindows of each indicated technology area into weapons IM fixprograms. The years given are for 40%/80% transition readiness.The 40% readiness window represents the situation when theweapons program must do 60% of the technology development toaffect the transition. The 80% readiness window represents thesituation in which the IMAD program has done 80% of the

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technology development and each weapon program only has to do ithat amount which is very weapon specific (estimated to be about20%). Major long range effort will focus on transition of hazardreduction technology into Navy weapon systems. Significanteffort beyond 1990 will concentrate on demonstrating the hazardreduction provided by advanced propellants in the hardwaredeveloped and demonstrated by this project. Additional effort iwill focus on advanced technology applicable specifically to thenew advanced propellants.

FUNDING: Funding required to support this project is summarizedby fiscal year and task in Table Il.

TABLE I. TECHNOLOGY TRANSITION WINDOWS FOR ROCKET MOTOR IM FIXESPRESENT PERFORMANCE LEVELS40A10% Readiness in FYs Shown

ThreatsI

Fix Technology SD 1 FCO FraSSD CO FI SCO EMP 8

Initiating systems 86/90 /90 86/90Propellants 89/90 86/91 8W192 88/92 88/92Alternate propulsion 91/95 91/95 91/95 91/95 91/95CasesI

strip laminate 86188 89/91 86/89composite 88/90 90/92 88/91 8&g2hybrid 90/92 90/92 90/92 90/92

Liners 90/92 90/92 90/92Coatings 86/89

Container 90/92 90/92 90/92 90/92 /86 90/92Storage 86/88 [1

Mitigation Devicesretrofit 88/ 8 88/forward fit 88/ 88/ 88/

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Task Title: Coordination and Technical DirectionTask Number: 4000Principal Investigator: Andrew Victor, NWC/CL, Code 32051, X7391

OBJECTIVE: Provide management and coordination of the entireproject. Provide for sponsor liaison, overall coordination ofthe tasks within the project, administrative support, overallcontract support, coordination with other projects of the IMADprogram, coordination with Navy weapons programs and with relatedprograms in the other services, industry and allied nations.

BACKGROUND: NAVSEA identified the Naval Weapons Center as thelead laboratory for the propulsion project of the IMAD program.This task provides support for personnel required to performplanning, coordination, administrative support, reporting, and

* liaison functions for the project.

APPROACH: Establish and maintain the management andadministrative staff, technical support, and program structurethat will result in timely development and demonstration ofpropulsion technology to meet the requirements of NAVSEAINST8010.5. Attend necessary meetings and conferences, prepare andpresent plans and reports and provide any other inputs orcoordination required by the sponsor. Enlist the support ofindustry and other government agencies toward the IMAD programobjectives by preparing papers and presentations for appropriateforums. Provide overall contractor support and funding for jointservice IM tasks.

PROGRESS (FY88): Continuing coordination with major propulsioncompanies was highlighted by a joint government/industry meeting onInsensitive Propellants Requirements at NWC in June 1987.Numerous papers and presentations were promulgated to help defineIM requirements and establish proper directions for industrialand government efforts. Coordination activities in JANNAF haveled to formation of the new Insensitive Munitions InformationCenter Subcommittee and a new IM Panel. Coordination activitiesthrough TTCP have led to formation of a new WAG (W-Action Group)on propellant and explosive sensitivity. Working under contractto this task, COMARCO completed charts of Production Schedules/IMPlans for all major Navy munitions, worked on the IM data base,supported definition of blast overpressure measurementrequirements, and served as an important link for IM technologyneeds definition for weapon system support. A joint bulletimpact study between NWC and MICOM was started. A Small BusinessInnovative Research (SBIR) project on advanced rocket motor casedesign was initiated. Support continued for the NATO-FTE projectcombining rocket propellant and motor case technologies which wasdefined under this project and transitioned to NAVAIR forsupport, redefinition, and management. The major focus of theNATO-FTE is IM. International coordination with French, British,and Australian scientists was extremely profitable to the projectin terms of new technology made available for U.S. use on the IM

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PLANS (FY89-FY92): Plans and major milestones of the task aredirected toward having IM technologies developed anddemonstrated, through the other tasks in the project, to provideengineering of these technologies into munitions in a timelymanner. Refer to the milestones of the other tasks. IFY89

-Continue and expand cooperative programs (ongoing task).-Institute protocol and prc¢;edures for qualifying Iinsensitive propellants.

-Update and maintain data base for IM propulsion/propellants.-Support transition of demonstrated technologies.

FY90-Continue and expand cooperative programs (ongoing task).-Continue to update and maintain data base for IMpropulsion/propellants.

-Continue to support transition of newly demonstratedtechnologies.

FY91/FY92-Continue to expand cooperative programs (ongoing task).-Continue to update and maintain data base for IMpropulsion/propellants.-Continue to support transition of newly demonstratedtechnologies.

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I Task Title: Rocket Motors and Large-Scale TestingTask Number: 41003 Principal Investigator: James Farmer, NWC/CL, Code 3274, X7504

OBJECTIVE: The objective of this task is to develop anddemonstrate IM technology directly applicable to operationalrocket motors. This involves acquisition and testing of rocketmotors incorporating baseline and advanced cases and propellants,advanced initiation systems, and alternate propulsion concepts.This task coordinates all of the rocket motor work on the projectincluding hazard and performance test management.

I BACKGROUND: The existing data base on rocket motor sensitivityis not adequate to support rational design of motors that meet IMrequirements. This task will augment that data base and apply itto demonstrate advanced propellants, cases, and alternatepropulsion systems that meet IM requirements.

APPROACH: This task has instituted the first systematic test ofthe propellants in our current advanced performance inventory.The results of these tests provide a baseline for evaluation ofcurrent technology in terms of both sensitivity and the abilityof small scale tests to predict munition sensitivity.Simultaneous small scale test studies of the baseline propellantsare performed in Task 4120. In the out years hazard testing willcontinue with advanced propellants in the generic rocket motorcases. Improved testing methods and instrumentation are alsobeing investigated under this task. This task provides advanced3 development applicable to all air ana surface launched missiles.

PROGRESS (FY88): Large-scale IM hazard tests of baselinepropellants (reduced smoke and high aluminum HTPB composite) ingeneric monolithic steel, composite, and strip-laminate caseswere completed and reported (NWC TP 6840). The maximumperformance Class 1.3 propellant was loaded in generic cases forIM testing. Additional large scale hazard tests were run forHellfire motors and Rapier motor cases containing RDX loadedEMCDB propellant. Tests were also run on several other rocketmotors, and test preparation for Alternate Pronulsion Systems(bipropellant gel) was started. Intermediate cook-off tests werestarted.

PLAN (FY89-92): Plans and major milestones of the task area byfiscal year are as follows:

FY89-Continue large scale hazard tests on generic motors.-Propulsion performance tests of generic rocket motors withadvanced propellants will be run as needed.

-Begin large scale hazard tests of advanced propellants.

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-Expand large scale hazard test program to include advancedcase concepts.

-Complete intermediate cook-off investigation.-Continue hazard tests of alternate propulsion systems.

FY90-Propulsion performance tests of generic rocket motors withadvanced propellants will be run as needed.-Continue large scale hazard tests of advanced propellantsand advanced case designs.

-Continue tests of alternate propulsion systems.-Support special IM test requirements of weapon systems.

FY91/FY92 U-Complete tests of alternate propulsion systems.-Continue hazard tests of advanced propellants and cases.-Transition IM propulsion technology to weapon systems.

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I Task Title: Prop. llantsTask Number: 4200Principal Investigators: E. Panella, NWC/CL, Code 3274, X7305

J. Kelley, NSWC/IH, Code RIOE, X4791

3 OBJECTIVE: The objective of this task is to provide insensitivepropellants that meet the Navy's requirements for performance andIM, and examine alternate propulsion concepts.

BACKGROUND: Propellants that meet performance requirements forhigh energy delivered at appropriate rates, low signature, andinsensitivity are required to satisfy the Navy's IM policy. Somemissiles show an urgent neeu for new propellants to satisfy theserequirements. Generic vulnerability tests of propellants must beperformed with real rocket motors. Therefore, standard designpractice and standard rocket motor fabrication techniques areused to produce the generic units. Small-scale tests arerequired to characterize propellant insensitivity prior to scale-up and generic motor loading. Immediate applicability of thistask to HARPOON, HELLFIRE, ASROC, STANDARD MISSILE, SIDEWINDER,TOMAHAWK, TOW, STINGER, and Wide Area Missile has been

* identified.

The propulsion work that is described in other task areas isdevoted to concepts in which propulsion is provided by a singlesolid propellant grain in a structural container. Under thistask, alternate concepts, such as gelled fuel/oxidizer systems,solid bipropellant systems, and hybrid propulsion systems will beconsidered. For those examined that show promise, they will bedeveloped and demonstrated. Some have been investigated on priorexploratory development projects by various services (mostrecently, Army/MICOM work on TRW/Talley bipropellant gels).

APPROACH: This task comprises sensitivity, formulation, andproducibility evaluation of advanced propellants. As part of therequirement to provide satisfactory propellants, candidateformulations will first be tested (characterized) on a smallscale to select for scale-up only those that are expected to meetrequirements for sensitivity and performance. This will requirethe development and application of small scale test andanalytical techniques, the generation of data on a variety ofexisting formulations, and the correlation of generated andalready existing data to predict responses of new propellants toIM stimuli in large scale testing. This task further includesthe tailoring of advanced formulations for easy producibility,loading, and grain design, and will be supported in the loadingand large scale testing of new formulations in generic cases byTask 4100. In-house and contractor sources will be employed.The actual selection of formulations will be based on technicaldata generated, as well as on cost and schedule. Within theFY86-FY88 effort five conventional tactical propellants (reducedsmoke [SIDEWINDER], minimum smoke [HELLFIRE], conventional

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aluminized HTPB [MK-lll], high energy advanced composite ipropellant [MK-104], and a high energy variant of the British-developed elastomer modified cast double base [EMCDB] propellant)have been evaluated. Much generic case loading and large scaleIM hazard testing of these propellants was accomplished duringFY87/88. In the outyears more advanced propellants will beloaded. Some of these are just emerging from the 6.2 propulsion Uprogram now; others are still being developed.

Activity on alternate propulsion concepts started in FY87.For all proposed concepts, performance analyses and small scale itests will b performed early and in conjuntion the 6.2 propulsionprogram and with related work in the other services, to determinefeasibility. In general, if the concepts have the potential toprovide the necessary performance, relatively low costvulnerability tests of propellant containers will be performedbefore going to the expense of developing functioning propulsion Iunits. Only when adequate insensitivity and performancepotential have been demonstrated will propulsion demonstrationmotors be fabricated and tested. 3PROGRESS (FY88): Test samples of the five conventionalpropellants selected for baseline tests on the project have beenevaluated in small and large scale tests. The tests include Ismall scale characterization, sensitivity, and hazard outputtests, and large scale IM tests in conventional and advancedmotor cases. Several new small scale sensitivity and hazard testmethods have been investigated, developed, demonstrated, anddocumented. The small scale investigations of conventionalpropellants is well under way. The results of some of thesestudies have been rather startling; and, as a result, we anticipatemajor improvements to be forthcoming in widely accepted methodsof characterizing propellants for IM in the near future.Priorities for insensitive propellant development were identified Iand incorporated in both Navy in-house propellant formulationsubtasks and industrial development.

Energetic materials with the potential to replace HMX and RDX in ihigh energy propellants have been evaluated by a computer basedperformance optimization technique. Advanced ingredient scale-upto obtain these and other ingredients for propellant formulationswas started in FY87. Resulting reduced sensitivity propellantsare in development. 3Under development in-house are 1) slow cook-off mitigatingpropellants, 2) low pressure extinguishing propellants, 3) TPEpropellants, 4) high energy/density propellants for volumelimited applications, 5) "homogeneous" propellants, and 6)rugged non-detonable minimum signature propellants. Thesesubtasks are in accord with the identified priorities for Navyinsensitive propellant development. I

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I Progress (FY88) (Cont'd):

Regular contact with industry has been maintained for their newideas, their support in obtaining conventional and advancedpropellants, and for participation in the JANNAF and TTCP forums3 on IM.

In response to our publication of a Broad Area Announcement inthe Commerce Business Daily for insensitive propellantdevelopment, 12 industry proposals were received. Theseproposals meet the identified priorities for Navy insensitivepropellants by a number of different approaches.

* Alternate propulsion concepts started in FY87 withacquisition of tankage for containing bipropellant gel materialsduring IM hazard tests. In FY88 a contract was awarded tomanufacture and load gelled fuel and oxidizer. Analyses of thegel propellant performance in Navy missiles were performed.

PLANS (FY89-FY92): Plans and major milestones of this task areaby fiscal year are as follows:

FY89-Initiate additional industrial development contracts forinsensitive propellants.

-Complete small scale propellant tests on baselineconventional propellants.-Perform analytical performance study of newly identifiedadvanced propellants.

-Identify additional candidate Navy developmentalpropellants for outyear IM advanced development and futurescale-up.

-Complete correlation of large scale and small scale testresults on baseline conventional propellants; publish theresults.-Perform small scale tests on selected Navy and industrydevelopmental propellants.

-Begin advanced developmental (scale-up and test) ofselected Navy developmental propellants.

-Load developmental insensitive propellants into genericmotor cases for large scale IM hazard vulnerability testingunder Task 5100.

-Begin small scale tests of other service and industrypropellants, new propellants with advanced ingredients, andother propellant advances.-Complete verification of insensitive propellantcharacterization protocol and procedure.

-Establish prediction methodology on basis of large andsmall scale test results and scientific principles.-Continue evaluation of advanced propulsion concepts as IMalternatives.-IM hazard tests on bipropellant gel alternate propulsionsystem.

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Plans (FY89-FY92) (Cont'd): UFY90

-Continue industry advanced propellant development.-Continue small scale tests of advanced propellants.-Identify critical variables for "propellant qualification"from results of this project.

-Load developmental insensitive propellants into genericmotorcases for large scale IM hazard vulnerability testingunder Task 4100.-Continue advanced development (scale-up and test) ofselected developmental propellants, and add advancedpropellants.

-Begin loading of viable other service and industrypropellants into generic cases for large scale hazardtests.

FY91/92-Continue industrial advanced propellant development.-Continue small scale tests and evaluation of newly emergingpropellants.-Continue to improve prediction methodology.-Continue advanced development (scale-up and test) ofselected advanced propellants. m

-Load additional advanced propellants for hazard testingunder Task 4100.

-Document results and recommendations based on the program. 3

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U Task Title: Advanced CasesTask Number: 43005 Principal Investigator: J. Farmer, NWC/CL, Code 3274, X7504

OBJECTIVE: The objective of this task is to develop anddemonstrate advanced rocket motor case concepts that reduce thesensitivity and/or hazardous output of rocket motors subjected toinadvertent stimuli, and to acquire generic rocket motor casesfor use in large scale hazard vulnerability testing of3 propellants and rocket motors.

BACKGROUND: The confinement provided by rocket motor cases is amajor factor in the level of response of rocket motors to variousunplanned stimuli. In this project, generic rocket motors ofvarious design concepts will be developed for evaluation invarious vulnerability tests in Task 4100 in accordance with therequirements of NAVSEAINST 8010.5. Generic motors will bedesigned to meet specific requirements so the effects of changesin propellants on sensitivity and reaction severity can beevaluated. This task is directly applicable to STANDARD MISSILE,HARM, HARPOON, ASROC, SIDEWINDER, TOMAHAWK, SEA LANCE, HELLFIRE,TOW, STINGER, and PENGUIN.

* APPROACH: Cases will include monolithic steel cases of theSkipper (Shrike) design and cases made of alternate materials(strip laminate, graphite/epoxy composite, and various hybriddesigns) fabricated to the Skipper performance requirements.Design methods will be developed and evaluated for tailoringcases to mitigate specific hazard threat stimuli. Case conceptsdesigned specifically for their ability to mitigate certainhazards will be acquired for testing. Hazard mitigation systems,where necessary, will be tailored for the specificcharacteristics of the cases. Supporting design work planned inthe Navy's 6.2 propulsion program will address new concepts anddesign methods and design requirements due to operationalstresses in Navy missions. Results of a current SBIR contract on3 shock attenuating cases (SPARTA, Inc.) will be incorporated.

PROGRESS (FY88): Sixty conventional steel baseline genericcases, 25 composite cases, and 20 strip laminate cases wereacquired during FY88. An SBIR contract on "tuned" motor caseswas completed (with SPARTA, Inc.) with a recommendation to go tophase II. The concept of a tuned motor case is to tailor thecase to specifically attendate shock pressure into thepropellant, and thus reduce the probability of detonation inresponse to high velocity fragment imracts. Design efforts onhybrid and composite cases were aborted in FY88 due to fundingcuts.

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PLANS (FY89-FY92): Plans and major milestones of the task are asfollows:FY89 I

-Continue generic motor case acquisition for advancedpropellant IM tests.-Continue study of advanced case concepts and of design Imethods for insensitive rocket motor cases with specificemphasis on composite and hybrid cases.

-Fabricate and start tests of first advanced "tuned" cases(if current SPARTA contract is technically successful).

FY90-Continue generic motor case acquisition for advancedpropellant IM tests.-Complete and document study of advanced case concepts andof design methods for insensitive rocket motor cases. I-Acquire generic motor cases for larger diameter and higherpressure analogs.-Continue case development and acquisition.-Start acquisition and test of motor cases based on new Udesign rethodologies.

FY91 i-Perform IM tests of advanced case concepts with baselinepropellants for concept evaluation.-Continue generic motor case acquisition for advancedpropellant IM tests.

-Continue acquisition and test of motor cases based on newdesign methodology.

FY92-Transition appropriate advanced case technology to weaponsystems. I

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I Task Title: Mitigation SystemsTask Number: 44003 Principal Investigator: A. Diede, NWC/CL, Code 3273, X7328

OBJECTIVE: The objective of this task is to provide mechanicaland thermal means for mitigating the hazards of rocket motorssubjected to the entire range of threat stimuli specified inNAVSEAINST 8010.5A.

BACKGROUND: Under various exploratory and advanced developmentprograms, a number of means of mitigating (that is reducing theseverity of) munition responses to hazardous stimuli have beendemonstrated. Some of these concepts, like alternate rocketmotor cases (strip laminate, composite, hybrid, etc.) havedemonstrated mitigation in fast cook-off, slow cook-off, andbullet impact tests. Active mitigation devices, like the TCP andTIVS developed by the NAVAIR IM Technology Transition Program(IMTTP) are designed to work only against the fast cook-offthreat. Active mitigation devices for slow cook-off have beendevised and demonstrated under this task of the IMAD program.Problems are encountered in devising active mitigation devicesfor impact threat stimuli because the reaction times must be veryshort. Even though we have demonstrated successful case ventingactive mitigation systems for some bullet impact stimuli, it willbe necessary to develop passive systems (case designs combinedwith propellant changes) for general, and completely reliablefixes.

APPROACH: Identify promising active mitigation device concepts,develop new concepts, select those concepts most likely toproduce devices suitable for Fleet use. Conduct subscale andfull-scale tests to demonstrate feasibility and proof-of-conceptand select those concepts which will enter full development. InFY86 this task area concentrated on preliminary design andevaluation of a wide variety of mitigation concepts. Several ofthese preliminary designs were selected for further advanceddevelopment in FY87 and FY88. Close coordination with the NAVAIRIMTTP is maintained.

PROGRESS (FY88): Over one dozen new hazard mitigation systemswere conceptualized in FY86. Hardware for several of these wasfabricated and feasibility tests were performed. Two designs forscaled up development and demonstration on full size rocketmotors were selected as the major foci for FY87. Both approachesfocused on retrofitable systems to mitigate fast cook-off. Oneof the approaches was also designed for applicability to slowcook-off and bullet and fragment impact threats. This involved a"quad-function" mitigation system designed and successfully

tested in FY87 and FY88 to mitigate fast and slow cook-offreaction violence and also some bullet impact threats. Work onthe concept that focused on a removable mitic'ating "belt,"designed mainly for fast cook-off mitigation on air-launched

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missiles, was stopped early in FY88 due to budget cuts. IWork on mitigation systems was concluded for this task duringFY88 with successful proof-of-concept demonstration of the "quad-function mitigation system" and preparation of a report of thework done (NWC TP 6849).

PLANS (FY89): Plans for FY89 involve minor work in an advisory 3capacity and presentation of the results of this completed task.

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U Task Title: Ignition SystemsTask Number: 45005 Principal Investigator: TBD

OBJECTIVE: The objective of this task is to reduce the effect ofinitiation systems on the sensitivity and hazardous output ofrocket motors subject to inadvertent stimuli.

BACKGROUND: The initiation system is sometimes the mostsensitive part of a rocket motor, resulting in a markeddifference in response depending on whether or not the initiationsystem is directly impacted by hazard stimuli. In some systems(2.75" FFAR and ZUNI) there is no safe-and-arm link in theigniter; such igniters are susceptible to EMP.

APPROACH: Determine, by hazard testing and assessment, thesensitivity and output of different ignition systems and theireffects on rocket motor hazard responses. Develop anddemonstrate improved ignition systems which reduce the hazardresponses of rocket motors.

I PROGRESS: Effort on this task has not started.

PLAN (FY89-FY92): Plans and major milestones of this task areaby fiscal year are as follows:I FY90

-Appoint task leader and plan approach.-Perform initial sensitivity tests.-Start test item acquisition.

FY91-Install test items in baseline generic motors for hazardtesting.

FY92 -Perform hazard tests.

-Assess hazard test results.-Design improved initiat.on systems for hazard reduction.-Test improved initiation systems in generic/munitionhardware.-Transition improved initiation system to weapon systems.

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APPENDICESIIIIIIIIII

APPENDIX AGLOSSARY OF TERMS

ABBREVIATION TERM

ADP AUTOMATED DATA PROCESSINGADPA AMERICAN DEFENSE PREPAREDNESS ASSOCIATIONAEPS AIRCREW ESCAPE PROPULSION SYSTEMBI BULLET IMPACTBOD BOARD OF DIRECTORSCAD CARTRIDGE ACTUATED DEVICECNO CHIEF OF NAVAL OPERATIONSDEA DATA EXCHANGE AGREEMENTDOD DEPARTMENT OF DEFENSEDOE DEPARTMENT OF ENERGYDTA DIFFERENTIAL THERMAL ANALYSISEAD EXPLOSIVES ADVANCED DEVELOPMENTEMCDB ELASTOMER MODIFIED CAST DOUBLE BASEEMI ELECTROMAGNETIC IMPULSEEMP ELECTROMAGNETIC PULSEESD ELECTROSTATIC DISCHARGEFCO FAST COOK-OFFFI FRAGMENT IMPACTFLSC FLEXIBLE LINER SHAPED CHARGEGTU GENERIC TEST UNITHE HIGH EXPLOSIVEHWPTU HEAVY WALL PENETRATOR TEST UNITIM INSENSITIVE MUNITIONSIMAD INSENSITIVE MUNITIONS ADVANCED DEVELOPMENTIMC INSENSITIVE MUNITIONS COUNCILIMCG INSENSITIVE MUNITIONS COORDINATION GROUPIMIC INSENSITIVE MUNITIONS INFORMATION CENTERIMO INSENSITIVE MUNITIONS OFFICEIMTIC INSENSITIVE MUNITIONS TECHNOLOGY INFORMATION CENTERIMTTP INSENSITIVE MUNITIONS TECHNOLOGY TRANSITION PROGRAMJANNAF JOINT ARMY, NAVY, NASA, AND AIR FORCEJOCG JOINT ORDNANCE COMMANDER'S GROUPLANL LOS ALAMOS NATIONAL LABORATORYLLNL LAWRENCE LIVERMORE NATIONAL LABORATORYLOVA LOW VULNERABILITY AMMUNITIONLSGT LARGE SCALE GAP TESTMCAAP MCALESTER ARMY AMMUNITION PLANTMCX NON-AQUEOUS SLURRY EXPLOSIVEMICOM ARMY MISSILE COMMAND, HUNTSVILLENAVAIR NAVAL AIR SYSTEMS COMMANDNAVSEA NAVAL SEA SYSTEMS COMMANDNAVSEAINST NAVAL SEA SYSTEMS COMMAND INSTRUCTIONNESIP NAVAL EXPLOSIVE SAFETY IMPROVEMENT PROGRAMNFTU NATRUALLY FRAGMENTING TEST UNITNOS/IH NAVAL ORDNANCE STATION, INDIAN HEADNSRDC NAVAL SHIP RESEARCH AND DEVELOPMENT CENTER, CARDEROCKNSWC/D NAVAL SURFACE WARFARE CENTER, DAHLGRENNSWC/WO NAVAL SURFACE WARFARE CENTER, WHITE OAK

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APPENDIX A

ABBREVIATION TERM

NUSC NAVAL UNDERWATER SYSTEMS CENTER, NEWPORTNWC/CL NAVAL WEAPONS CENTER, CHINA LAKENWS/E NAVAL WEAPONS STATION/EARLENWS/Y NAVAL WEAPONS STATION, YORKTOWNNWSC, CRANE NAVAL WEAPONS SUPPORT CENTER, CRANEOPR OFFICE OF PRIMARY RESPONSIBILITY UPAD PROPELLANT ACTUATED DEVICEPBX PLASTIC BONDED EXPLOSIVEPC PERSONAL COMPUTERPOA&M PLAN OF ACTION AND MILESTONESPOC POINT OF CONTACTR&D RESEARCH AND DEVELOPMENTRCT REACTIVE CASE TECHNOLOGY IRCW REACTIVE CASE WARHEADS&A SAFE AND ARMSBIR SMALL BUSINESS INNOVATIVE RESEARCHSCO SLOW COOK-OFFSD SYMPATHETIC DETONATIONSMCA SINGLE MANAGER FOR CONVENTIONAL AMMUNITIONSNL SANDIA NATIONAL LABORATORYSYSCOM SYSTEMS COMMANDT&E TEST AND EVALUATIONTAIS THERMALLY ACTIVATED INTERVENTION SYSTEM iTASAD THERMALLY ACTIVATED SAFE AND ARM DEVICETC TECHNICAL COORDINATORTCP THERMAL COATED PROTECTIONTIVS THERMALLY INITIATED VENTING SYSTEMTTCP TECHNICAL COOPERATION PANELUSMC UNITED STATES MARINE CORPSUTU UNDERWATER TEST UNITWFCP WEAPONS FAST COOK-OFF PROGRAMWPE WORKING PARTY FOR EXPLOSIVES

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U APPENDIX BTELEPHONE EXCHANGESI

The Navy activity, mailing code and telephone extension foreach of the principal investigators is given in the text of theprogram plan. The commercial and Autovon telephone exhcanges foreach activity are as follows.

Activity Commercial Autovon

Naval Sea Systems Command (703) 692-XXXX 222-XXXXWashington, D.C. 20362-5101

Naval Surface Warfare Center (202) 394-XXXX 290-XXXXWhite Oak LaboratorySilver Spring, MD

Naval Surface Warfare Center (703) 663-XXXX 249-XXXXDahlgren, VA

Naval Surface Warfare Center (301) 743-XXXX 364-XXXXIndian Head, MD 20640-5000

Naval Weapons Center (619) 939-XXXX 437-XXXXChina Lake, CA

Naval Ordnance Station (301) 743-XXXX 364-XXXXIndian Head, MD 20640-5000

I Naval Ordnance Station DetachmentNEDEDYorktown, VA

Naval Weapons Station (201) 577-XXXX 499-XXXXEarle, NJ

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