IMX-104 Manufacturing Process Optimization Insensitive ... · PDF fileInsensitive Munitions &...
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Not Export Controlled – Releasable to Foreign Persons (S2DSEA2013-0502) Abstract # 16264 2013 Insensitive Munitions and Energetic Materials Technology Symposium San Diego, CA 1 IMX-104 Manufacturing Process Optimization Insensitive Munitions & Energetic Materials Technology Symposium 2013 Sean Newland*, Virgil Fung, Ben Schreiber, Alberto Carrillo, Michael Johnson BAE SYSTEMS Ordnance Systems Inc. Holston Army Ammunition Plant Kingsport TN, USA
Transcript of IMX-104 Manufacturing Process Optimization Insensitive ... · PDF fileInsensitive Munitions &...
Not Export Controlled – Releasable to Foreign Persons
(S2DSEA2013-0502)
Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
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IMX-104 Manufacturing Process Optimization
Insensitive Munitions & Energetic Materials Technology Symposium 2013
Sean Newland*, Virgil Fung, Ben Schreiber, Alberto Carrillo, Michael Johnson
BAE SYSTEMS Ordnance Systems Inc.
Holston Army Ammunition Plant
Kingsport TN, USA
Not Export Controlled – Releasable to Foreign Persons
(S2DSEA2013-0502)
Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Acknowledgements
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US ARMY RDECOM • Army ManTech Funding
US ARMY PEO-AMMO Project Manager Combat Ammunition Systems (PM-CAS) Leila Zunino • Stakeholder
US ARMY RDECOM-ARDEC Munitions Engineering & Technology Center (METC) Paul Vinh, XueLing Zhao • Engineering & Technical Lead • Producibility Support Project Integration Office (PIO) • Program Support
BAE SYSTEMS •Research & Development Analytical Labs •Production / Design Teams
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Outline
• Objective
• Background
• Approach
• Process Flow Diagram
• Design of Experiments (DOE)
• Brookfield Viscometer
• Dewatering Techniques
• Schedule
• Major Accomplishments & Status
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Objective
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• To maximize the manufacturing efficiency of IMX-104 to lower its unit
cost while maintaining the desirable properties.
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
IMX-104 Background
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• An insensitive melt-pour explosive to replace
Composition B for Mortar Applications
• IMX-104 and all starting ingredients manufactured at
Holston Army Ammunition Plant
• Exhibited superior IM properties and comparable
performance over Composition B in 81mm Mortar HE
• IMX-104 will minimize collateral damage when it is
exposed to unplanned stimuli including fires, shock
and impact
• IMX-104 qualified as an main fill explosive in June,
2011
• Type qualification on-going for 60 & 81mm Mortar HE
(120mm to follow)
• Over 100,000 LB. manufactured at HSAAP
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Approach
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• Test Plan Development
• Laboratory Scale Evaluation
• Effect of ingredient variation on processability
• Manufacture of Design of Experiment (DOE)
Batches
• Pre-Melter Feasibility Study
• Manufacture of FAT Batches
• Conduct
• First Article Tests
• Loading Study
• Brookfield Viscosity Measurement
Development
• Improve Raw Ingredients Dewatering
Technique
Lab-scale Melt Kettle
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Process Flow Diagram
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Incorporation
kettle
Hold-Up
Kettle Pellet
Pot
Melt M
ediu
m
& I
ngre
die
nts
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Design of Experiments
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Variables Conditions
Baseline 1,325 lb batch
Ingredient addition temp @ 105oC
Final mixing time & temp 90 minutes @ 100oC
DNAN Pre-Melter Various loading methods of DNAN
Various steam supply levels
Process Temperature Elevated ingredient addition and processing temperature
Ingredients Addition Rate Fastest possible addition rate without compromise on product
temp in kettle
Final Mixing Time & Temperature Reduced mixing time combined with higher mixing temperature
Batch Size High and low (1,500 lb / 700 lb)
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Pre-Melter
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Incorporation
kettle
Hold-Up
Kettle Pellet
Pot
Melt M
ediu
m
& I
ngre
die
nts
Ingredients
Pre-
Melter
Melt Medium
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Brookfield Viscometer
• Brookfield Viscometer is a rotational
viscometer
• Torque required to turn an object in a
fluid is a function of the viscosity of
the fluid.
• Relatively reliable and repeatable
• Much more sensitive than Efflux
viscosity measurement
• Less subjective, less operator
dependent measurement
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Dewatering Techniques
• Existing dewatering infrastructure
‒ Labor intensive
‒ Time consuming
‒ Inconsistent moisture content
‒ Extensive maintenance
• Bladder press
‒ Commercially available
‒ Rubber bladder expands with water pressure to press material against the basket to remove water
• Filter Press
‒ Commercially available
‒ Widely used liquid/solids separation equipment
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Bladder Press (Top), Filter Press (Bottom)
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Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Schedule
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Not Export Controlled – Releasable to Foreign Persons
(S2DSEA2013-0502)
Abstract # 16264
2013 Insensitive Munitions and Energetic Materials Technology Symposium
San Diego, CA
Major Accomplishments / Status
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• Completed Tasks
• Laboratory scale evaluation of raw ingredients characteristics
• Manufacture of DOE batches
• Prove-out of pre-melter
• Manufacture of FAT batches using optimized process parameters
• Development of Brookfield viscosity test method
• Planned Activities
• 81mm mortar loading study
• Raw ingredients dewatering study
