DoD MEMS Fuze Reliability Evaluation · DoD MEMS Fuze Reliability Evaluation 58th Annual NDIA Fuze...

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DISTRIBUTION A. Approved for public release: distribution unlimited. DoD MEMS Fuze Reliability Evaluation 58 th Annual NDIA Fuze Conference, Baltimore, MD Thursday, July 9 th 2015, Open Session VA, 14:00 Presented by Daniel Lanterman (NSWC IHEODTD) for: Taylor T. Young NSWC IHEODTD Jeffrey Smyth U.S. Army ARDEC Picatinny Arsenal RDAR-MEF-F Fuze Division

Transcript of DoD MEMS Fuze Reliability Evaluation · DoD MEMS Fuze Reliability Evaluation 58th Annual NDIA Fuze...

Page 1: DoD MEMS Fuze Reliability Evaluation · DoD MEMS Fuze Reliability Evaluation 58th Annual NDIA Fuze Conference, Baltimore, MD Thursday, July 9th 2015, Open Session VA, 14:00 Presented

DISTRIBUTION A. Approved for public release: distribution unlimited.

DoD MEMS Fuze Reliability Evaluation

58th Annual NDIA Fuze Conference, Baltimore, MD Thursday, July 9th 2015, Open Session VA, 14:00

Presented by Daniel Lanterman (NSWC IHEODTD) for:

Taylor T. Young

NSWC IHEODTD

Jeffrey Smyth U.S. Army ARDEC Picatinny Arsenal

RDAR-MEF-F Fuze Division

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MEMS Safe and Arm Chip

Set-back Lock

Command Lock

Slider

Initiator

Arming Micro Motor

Micro Detonator

Shown in Safe (unarmed) Position

Setback Lock

Command Lock Command

Armed Slider Front

Back

Micro-Detonator

Cup

MEMS based fuzing offers the potential for small volume, low cost, and low energy.

NSWC IHEODTD has been investigating silicon based MEMS for over a decade.

Can use either command arm/lock release motors or built in environmental sensors.

All non-explosive components fabricated on SOI wafers using established semi-conductor processes.

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MEMS Applications Hypervelocity Projectile 40 mm Grenade

High Reliability DPICMS Replacement (HRDR)

HRDR brief by Daniel Pines at 4:40 today in US only session

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Explosive Train Overview • Based on micro-detonator technology

developed at NSWC IHEODTD – Demonstrated to TRL6 in 40 mm

Grenade configuration

• Initiator fabricated onto the cap chip – Vaporizing metal foil bridge

• Pressed silver azide pellet assembled with the MEMS S&A chip

• Silver azide drives a flyer to initiate a lead

• Lead make 90° turn and initiates a booster

• Energetic components packaged in a metal fixture that is attached to an electronic PCB μDetonator Package

Output to Booster

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Navy Explosive Train (Basics)

MEMS Microdetonator 6 mg - φ2 mm Silver Azide

Booster Charge – RSI-007/PBXN-5

Lead –EDF-11

MEMS Chip Base Chip

Cap Chip

Secondary Lead (EDF-11)

RSI-007

Flyer Plate

HE-to-HE or

Flyer Contact

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Army Explosive Train (Basics)

MEMS Microdetonator

Energetic Ink

Booster Charge – EDF-11

Lead – EDF-11

MEMS Chip

Base Chip

Cap Chip

Lead (EDF-11)

Booster

(ED

F-11)

HE-to-HE Contact

Flyer Plate

Both detonators use stainless steel flyer plates

US Army AREDEC also has a MEMS Fuze effort.

Uses LIGA metal MEMS processes.

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Explosive Train Reliability

• MEMS intentionally pushes the lower limits of explosive component size. We want the smallest size detonators and leads that will work reliably.

• Target programs have strict reliability requirements. This is particularly true for HRDR which must comply with OSD’s policy of >99% reliability for cluster munitions.

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Brute force methods

Brute force demonstrations requires excessive number of shots to prove reliability. 99.9% Reliability @ 95% CL: 3000 Shots

0.7

0.75

0.8

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0.9

0.95

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10 100 1000 10000 100000

Rel

iabi

lity

Number of Shots Without Failures

0.00001

0.0001

0.001

0.01

0.1

1

1 10 100 1000 10000 100000 1-

Rel

iabi

lity

Number of Shots Without Failures

Binomial Reliability at 95% Confidence Level (one sided)

100 shot test series only demonstrates reliability to 97% (@ 95% CL)

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Background – Traditional Estimation Methods

Traditional Reliability Methods have imposed penalties on the system. These penalties are large enough to produce an observable failure rate. Reliability is obtained by extrapolating to zero penalty. Penalties take the form of gaps (Varigap testing), reductions in donor output either through reducing its density or using less powerful explosives (Varidrive testing) or using less sensitive acceptor explosives (Varicomp testing).

All of these methods are problematic at the MEMS scale. Varidrive and Varigap change the shock curvature generated. Changes to explosives in Varidrive and Varicomp are not advisable since MEMS systems are near critical diameter.

Flat Shock Curved Shock

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Background – A New Approach

• Separate response of donor and accepter at each interface.

Variation in Response of Acceptor

Variation in Response of Donor

Overlap – Probability of Failure

•Data can better be used to evaluate a family of similar designs.

•Data also provides more insight into the system and can be used to optimize design

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Background – Probabilistic Hugh James Space

0 0.5 1 1.5 2 2.5 30

0.5

1

1.5

2

2.5

3

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4

Σ = u2/2

E=P

u τ

50% reliability1% reliability99% reliability

Increasingreliability

1/J=Ec/E+Σc/Σ

Ec (critical minimum energy) & Σc (critical minimum ‘power’) are defined by the acceptor explosive material. E & Σ can be calculated from variable flyer and gap tests and inherent explosive properties. These methods were developed at AWE and LLNL and implemented at AFRL.

Hugh James formalism can be used to map out statistical response of acceptor explosive

0 0.5 1 1.5 20

0.2

0.4

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1

JP

roba

bilit

y

Normal distrubution about thresholdProbability of detonation transfer

Page 12: DoD MEMS Fuze Reliability Evaluation · DoD MEMS Fuze Reliability Evaluation 58th Annual NDIA Fuze Conference, Baltimore, MD Thursday, July 9th 2015, Open Session VA, 14:00 Presented

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Detonator Characterization

MEMS flyer velocities can be measured with PDV

Variability will be present in any system Need to shoot a sufficient number (100+) to fit to a statistical distribution. Exact number of shots needed depends on how quickly tails of distribution die off.

PDV system can also be used to measure pressure time histories for contact detonation interfaces.

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PDV Measurements Navy Army

PMMA

Barrel

SS Flyer

MEMS Initiator

AgN3

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PDV Results - Navy

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8 Co

unt

Bin

20 shots analyzed to date. Additional shots planed.

Standard deviation 4.7% of mean value.

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EDF-11 HJ Parameterization • Electric gun will be used to make

EDF-11 sensitivity measurements. • Conduct threshold testing at several

flyer thicknesses (0.5, 1, 2 & 3 mils Kapton)

• 1.6mm square flyer. Based on computer models of the flat section of MEMS flyer.

• Limited number of previous measurements at EFI relevant length scales, but spot size dependent.

Need to have Hugh James Initiation data at MEMS scales

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Flyer Measurements in HJ Space

E

Σ

Navy MEMS Data

Army MEM data

Remember: the Navy design uses a larger diameter flyer

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Previous EDF-11 Threshold Measurements

E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data

LLNL has made previous threshold measurements on EDF-11

These measurements were made at EFI length scales, and would be lower at larger spot sizes.

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Fit ill-defined E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data

These two points do not well define a hyperbolic fit.

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Proposed Measurement Paths E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data Threshold FIt

.5 mil flyer

1 mil flyer

2 mil flyer

3 mil flyer

Each flyer thickness defines a path through HJ space.

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Upcoming • Finish detonator experiments and fit distribution

function • Multiple threshold test series of EDF-11 in a

MEMS relevant Hugh James Space – 0.5,1,2, and 3 mil thick Kapton

• Transfer lead output test series – PDV measurements of lead output

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Conclusions • New explosive trains require new methods of analysis.

• These new methods can better aid intelligent design.

• We believe we have a reasonable path to demonstrate

reliability.

• Both and the Navy and Army are committed to ensuring that MEMS fuzing achieves the highest degrees of reliability possible.

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Acknowledgments Section: Thanks to the Joint Fuze Technology Program (JFTP) for funding this work.

Thanks to Chadd May and Lawrence Livermore National Labs (LLNL) for the loan of the

electric gun.

Thanks to those who have helped work on the project:

ARDEC Roger Cornell

Charlie Robinson Brian Fuchs

NSWC IHEODTD G. Shane Rolfe Jason Brindle Daniel Pines

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DISTRIBUTION A. Approved for public release: distribution unlimited.

Questions?