Co-Layered Propellant Manufacturing Richard S. Muscato Dr. Suzanne Prickett Christopher Gonzalez 29 October 2002.

Co-Layered Propellant Manufacturing

Richard S. MuscatoDr. Suzanne Prickett

Christopher Gonzalez

29 October 2002

Outline Description Milestones Capabilities Formulations Charge Design Benefits

Co-layered Gun PropellantSlower Burning Outer Layer

Faster Burning Inner Layer

Enhanced gun performance Increased charge weight Increased energy density Controlled pressurization

Closure Plug

Propellant Disks/Wraps

5” Cartridge CaseIgniter

3:1 Ratio

Project Description Objectives

Develop a process to manufacture co-layered propellant using two integrated twin screw extruders

Product performance Affordable process Reproducible process

Transition the technology to industry

Approach Integrated Product/Process

Development

Project Milestones FY 02:

Co-extrusion capability established Co-extrusion feasibility for gun propellants validated Propellant formulations and charge design defined Continuous twin-screw processing of each individual formulation

demonstrated

FY 03: Tooling design completed Tooling fabricated Post-extrusion process defined Initial process studies with co-extrusion system completed

FY 04: Process technology defined and demonstrated

FY 05: Optimized process technology transitioned to industry for

production

Previous Pilot Scale Capability

W&P ZSK-40 twin-screw extruder Process development facility (Class

1.1 – 700 lbs) Processing rates

10 - 30 lb/hr (gun propellant) 25 - 50 lb/hr (extruded propellant) 25 - 100 lb/hr (cast composite propellant/PBX

explosives)

Six solid feeders (four feedstreams simultaneously)

Four liquid pumps Limited automatic refill Product handling systems Extensive

instrumentation/diagnostics

W&P 40-mm extruderBuilding 1119

New Co-extrusion Capability Objective: Install a co-extrusion capability

at IHDIV to process a co-layered gun propellant using two integrated twin screw extruders

Construction complete: Installed; W&P 37mm TSE with an upgraded Kubik hydrostatic

drive Four temperature control units Zenith liquid feed system LIW vibratory tray solid feeder Remote vacuum pump system Material TPT’s along the TSE barrel length Accelerometer devices for vibration monitoring Independent Allan Bradley PLC control system with DAS

Facility Layout

Building Floor Plan

Feeder Arrangement

Co-Extrusion Capability

Y

Co-Extrusion Die

Co-Extrusion Capability

Co-Extrusion Capability

Co-Extrusion Capability

Propellant Formulations Investigated the effect of solid

additives on EX-99 nitramine gun propellant Burning rate additives identified

Batch mixes to downselect plasticizer Burning rates of final formulations

required to finalize charge design

Propellant Formulations

Burning Rate vs. Pressure

0.10

1.00

10.00

100.00

10000 100000Pressure (psi)

Burn

ing

Rat

e (i

n/s

ec)

Propellant Charge Design

Cord Disks

Concentric wrap

Closure Plug

Propellant Wraps

5” Cartridge CaseIgniter

5.2”

5”

Project Benefits Capability Increase

Gun Technology Improved performance

Safety Reduction of material in process Enhanced personnel safety

Environmental Reduction of waste propellant Minimization or elimination of solvents and associated wastes

Reliability improvements Improved bond integrity Better dimensional control Improved product quality

Labor Reduction in touch labor hours