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

2. Outline Description Milestones Capabilities Formulations Charge Design Benefits

3. Co-layered Gun Propellant Slower 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 Case Igniter 3:1 Ratio

4. 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

5. 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

6. 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 extruder Building 1119

7. 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 TPTs along the TSE barrel length Accelerometer devices for vibration monitoring Independent Allan Bradley PLC control system with DAS

8. Facility Layout Building Floor Plan Feeder Arrangement

9. Co-Extrusion Capability

10. Y Co-Extrusion Die

11. Co-Extrusion Capability

14. 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

15. Propellant Formulations

16. Propellant Charge Design Cord Disks Concentric wrap Closure Plug Propellant Wraps 5 Cartridge Case Igniter 5.2 5

17. 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