co-layered propellant manufacturing richard s. muscato dr. suzanne prickett christopher gonzalez 29...
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Co-Layered Propellant Manufacturing
Richard S. MuscatoDr. Suzanne Prickett
Christopher Gonzalez
29 October 2002
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Outline Description Milestones Capabilities Formulations Charge Design Benefits
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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
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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
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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
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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
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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
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Facility Layout
Building Floor Plan
Feeder Arrangement
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Co-Extrusion Capability
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Y
Co-Extrusion Die
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Co-Extrusion Capability
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Co-Extrusion Capability
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Co-Extrusion Capability
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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
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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)
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Propellant Charge Design
Cord Disks
Concentric wrap
Closure Plug
Propellant Wraps
5” Cartridge CaseIgniter
5.2”
5”
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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