Act like someone’s life depends on what we do. UNPARALLELED COMMITMENT & SOLUTIONS UNCLASSIFIED UNCLASSIFIED U.S. ARMY ARMAMENT RESEARCH, DEVELOPMENT & ENGINEERING CENTER Nanomaterials and Additive Manufacturing for Munitions Power Sources Giuseppe L. Di Benedetto, Ph.D. Advanced Materials Technology Branch U.S. Army ARDEC Picatinny Arsenal, NJ, USA, 07806 DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE DISTRIBUTION IS UNLIMITED
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Giuseppe L. Di Benedetto, Ph.D. - UMD...Giuseppe L. Di Benedetto, Ph.D. Advanced Materials Technology Branch U.S. Army ARDEC PicatinnyArsenal, NJ, USA, 07806 DISTRIBUTION STATEMENT
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Act like someone’s life depends on what we do.
UNPARALLELED
COMMITMENT
&SOLUTIONS
UNCLASSIFIED
UNCLASSIFIED
U.S. ARMY ARMAMENT
RESEARCH, DEVELOPMENT
& ENGINEERING CENTER
Nanomaterials and Additive Manufacturing for Munitions Power Sources
Giuseppe L. Di Benedetto, Ph.D.Advanced Materials Technology Branch
U.S. Army ARDEC
Picatinny Arsenal, NJ, USA, 07806
DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE DISTRIBUTION IS UNLIMITED
UNCLASSIFIED
UNCLASSIFIED
2DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE
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KEY CONTRIBUTORS
R. Carpenter – US Army ARDEC
D. Swanson – EnerSys Advanced Systems
B. Wightman – EnerSys Advanced
Systems
E. Handy – SI2 Technologies, Inc.
K. Maleski – Drexel University
T. Mathis – Drexel University
K. Van Aken – Drexel University
Y. Gogotsi – Drexel University
D. Sabanosh – US Army ARDEC
J. Zunino – US Army ARDEC
D. Schmidt – US Army ARDEC
J. Kraft – US Army ARDEC
L. Zunino – US Army ARDEC
B. Fuchs – US Army ARDEC
L. Holmes – US Army Research Labs
K. Duncan – US Army CERDEC
C. Haines – US Army ARDEC
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Army S&T Performing Organizations
Materiel
AMCArmy Materiel
Command
Personnel
G-1HQDA, G-1
Personnel
Medical
MEDCOMArmy Medical
Command
Infrastructure/Environmental
USACEArmy Corps of
Engineers
Strategic Missile Defense
SMDCArmy Space &
Missile Defense
Command
ATECArmy Test &
Evaluation Command
Test &Evaluation
RDECOMResearch,
Development &
Engineering
Command
AMRDEC
Aviation & Missile
Research,
Development &
Engineering
Command
ARL
Army Research
Laboratory
Armaments
Research,
Development &
Engineering
Command
Communications-
Electronics
Research,
Development &
Engineering
Command
Edgewood
Chemical Biological
Center
Natick Soldier
Research,
Development &
Engineering
Command
Tank-Automotive
Research,
Development &
Engineering
Command
ECBC NSRDECCERDEC TARDECARDEC
UNCLASSIFIED
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S&T IN RDECOM
XM25
Counter Defilade Target
Engagement System
Discovery Innovation Advanced
Development
Translational
Neuroscience
ARL
RDECs
PMs/PEOS
Engineering &
Production
Support to
Warfighter
Face-Gear
Technology for
Block III Apache
MRAP Armor
MEMS TBI
Sensor
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INTRODUCTION
Why is the Army looking at thermal batteries?:
Thermal batteries remain a key primary power source for critical military
applications, such as precision munitions and missiles.
Competitive technologies have yet to achieve the performance and reliability of
thermal batteries for these applications.
A more compact & powerful thermal battery will lead to increased lethality and
precision.
What does this study aim to accomplish?:
Use a fully scalable high energy milling method to produce kilogram quantities of
nanoscale FeS2, CoS2, NiS2 powders for thermal battery cathodes.
Understand the effect of process parameters on the resulting nanoscale powders.
Theory behind work being done:
Nanomaterials offer an opportunity to produce batteries with improved
performance, such as higher voltages and increased current densities.
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MATERIAL PROCESSING AND MIXING
Micron sized FeS2, CoS2, NiS2 powder are currently used in thermal battery
cathodes.
Through mechanical attrition, powder particle size is reduced to the nanoscale
High energy horizontal attritors used to impart nanostructure.
Provide extremely high amounts of kinetic energy
Processing carried out in inert atmosphere to minimize oxygen pickup.
RPM, Powder-Ball-Ratio (PBR), Processing time, and Media type all important
variables in tailoring material properties
Multiple experiments were performed with different processing times to achieve
desired powder properties
High Energy Mill Size reduction through particle
collisions with grinding media
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NiS2:
PROCESSED POWDERS
CoS2:
As-Received [Micron FeS2 (right)]
Processed [Nano FeS2 (left)]
FeS2:
As-Received [Micron CoS2 (right)]
Processed [Nano CoS2 (left)]
As-Received
[Micron NiS2 (right)]
Processed [Nano NiS2 (left)]
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CHARACTERIZATION TECHNIQUES
Scanning Electron Microscopy:
Zeiss Supra V40
X-Ray Diffraction
Rigaku Ultima
X-Ray Fluorescence
Rigaku ZSX Primus II
B.E.T.
Quantachrome Nova 4000e
ICP
Perkin Elmer Optima 5300V
LECO Sulfur Analysis
LECO SC632
Single Cell Thermal Battery Testing
from a Proven SANDIA design
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SCANNING ELECTRON MICROSCOPY – FES2
Scanning Electron Microscopy:
SEM was performed in order to estimate particle size.
Clear size reduction can be seen from top row (as-received) and the lower rows
(processed)
Magnifications (left to right) 500x,
2kx, 15kx, 25kx
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SCANNING ELECTRON MICROSCOPY – COS2
Scanning Electron Microscopy:
SEM was performed in order to estimate particle size.
Clear size reduction can be seen from top row (as-received) and the lower row
(processed)
Agglomeration of ultrafine particles was evident at low magnifications of processed
powder.
Magnifications (left to right) 500x,
2kx, 15kx, 30kx
As-Is
10h
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SCANNING ELECTRON MICROSCOPY – NIS2
Scanning Electron Microscopy:
SEM was performed in order to estimate particle size.
Clear size reduction can be seen from top row (as-received) and the lower row
(processed).
Agglomeration of ultrafine particles was evident at low magnifications of processed
powder.
Magnifications (left to right) 500x,
2kx, 15kx, 30kx
As-Is
10h
UNCLASSIFIED
UNCLASSIFIED
12DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE