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Hazard Assessment Testingof the SM-3 Block IA Missile
Presentation for theNDIA Gun and Missile Systems Conference
25 April 2007
Dave HouchinsDahlgren Division, Naval Surface Warfare CenterTest & Evaluation Division (Code G60)
Hazard Assessment Testing of the SM-3 Block IA Missile
Outline• Description of SM-3 Block IA missile• Hazard Assessment Test Program• Test methodologies• Summary of results• Lessons-learned
Hazard Assessment Testing of the SM-3 Block IA Missile
MK 72 Booster
MK 104 Dual ThrustRocket Motor
Third StageRocket Motor
GuidanceSection
Kinetic Warhead(inside Nosecone)
Nosecone
StagingAssembly
Steering Control Section
SM-3 Block IA Missile• Sea-based component of the Ballistic Missile Defense system• Launched from Vertical Launching System of DDG-class ships
– Approximately 22 ft length x 13.5 in diameter• MK 72 booster ~21 in diameter
– Contains ~2065 lbm propellant– Designed for MK 21 MOD 2 VLS canister
• Total mass of all-up round ~6300 lbm (i.e., missile and canister)• Exo-atmospheric intercept using Kinetic Warhead
Hazard Assessment Testing of the SM-3 Block IA Missile
Hazard Assessment Test Program for SM-3
Functional Testsof Components
Near Miss Shock
2005/2006SM-3 Block IA
Transportation VibrationShipboard Vibration
28-Day Temperature & Humidity
4-Day Temperature & Humidity
1999SM-3 Block 0
40-ft DropAft-end down
28 Day T&H
Fast Cook-offThird Stage Rocket Motor
Kinetic Warhead
4-Day Temperature & Humidity
Transportation VibrationShipboard Vibration
Launch Shock
28-Day Temperature & Humidity
SM-3 Block I2004
Slow Cook-offThird Stage Rocket Motor
Kinetic Warhead
40-ft DropHorizontal
Transportation VibrationShipboard Vibration
28-Day Temperature & Humidity
4-Day Temperature & Humidity
Fast Cook-offThird Stage Rocket Motor
Bullet ImpactThird Stage Rocket Motor
Kinetic Warhead
Fragment ImpactThird Stage Rocket Motor
Kinetic Warhead
Insensitive Munitions Tests(individual sections)
Environmental Tests(encanistered missile)
Hazard Assessment Testing of the SM-3 Block IA Missile
28-Day / 4-Day Temperature and Humidity (T&H) Test Method• Encanistered missile cycled between hot/humid and cold environments
– Conditions based on environmental profile for logistics life-cycle• +130F with 95% RH for hot/humid environment• -20F for cold environment
– 1 cycle includes 24-hr (min) exposure to each environment • Tests conducted using programmable environmental chamber• Test methods identical except for duration
– 14 cycles for 28-day T&H; 2 cycles for 4-day T&H
Time (hr)
Nominal RH(uncontrolled)
0
-20
60
-40
0
20
40
80
100
120
140
160
Tem
pera
ture
(°F)
010
20
30
40
50
60
70
80
90
100
5 10 15 20 25 30 35 40 45 50 55 60
Temperature
Relative Humidity
Rel
ativ
e H
umid
ity (%
)
Beginning ofNext Cycle
Hazard Assessment Testing of the SM-3 Block IA Missile
• Encanistered missile subjected to random vibration IAW MIL-STD-810– Simulate transportation by truck over improved roads– Input applied through 3 orthogonal axes; 1 axis at a time– 3 hr/axis duration to simulate 3000 miles over-the-road transport
• 2 hydraulic actuators used to provide input at each PHS&T skid
Transportation Vibration Test Method
Vertical Axis
Longitudinal Axis
Transverse Axis
Hazard Assessment Testing of the SM-3 Block IA Missile
Transportation Vibration Input Profile
5 10 20 50 100 200 500.00001
.00002
.00005
.00010
.00020
.00050
.00100
.00200
.00500
.01000
Frequency (Hz)
Pow
er S
pect
ral D
ensi
ty g
^2/H
z.0200
.0500
.1000
Vertical AxisTransverse AxisLongitudinal Axis
Hazard Assessment Testing of the SM-3 Block IA Missile
Shipboard Vibration Test Method• Encanistered missile subjected to random vibration to simulate shipboard
environment– Input profile and duration based on shipboard measurements in VLS cells
• 4 – 200 Hz frequency range• Input spectrum encompasses full range of ship speeds and sea states• 39-hr/axis to simulate anticipated deployment durations
– Input applied through 3 orthogonal axes; 1 axis at a time• System-specific tailored test requiring approval from NAVSEA 05T
– Most systems tested IAW MIL-STD-167• Sinusoidal vibration across 5 – 50 Hz frequency range
• Accomplished using UD-4000 electrodynamic shaker– Special fixtures used to provide input at correct interfaces with canister
Hazard Assessment Testing of the SM-3 Block IA Missile
Shipboard Vibration Input Spectrum
Hazard Assessment Testing of the SM-3 Block IA Missile
Transverse ShipboardVibration Fixture
UD 4000Shaker
VLS Dog-Down
Fixture
All-Up Missile inMK-21 Canister
DeckInterfac
eFixture
HydraulicBearings
Shipboard Vibration Test Setup (Transverse Axis)
Hazard Assessment Testing of the SM-3 Block IA Missile
Lateral SupportStructure
UD 4000Shaker
VLS Dog-down
Fixture
All-Up Missile inMK-21 Canister
Deck InterfaceFixture
Shipboard Vibration Test Setup (Longitudinal Axis)
Hazard Assessment Testing of the SM-3 Block IA Missile
Near Miss Shock Test Method• Accomplished using DS-3 Shock Machine
– Large-displacement, pendulum-type impact shock machine– Highly-tunable design
• Continuously adjustable pendulum impact velocity• Unique adjustable fixture permits input through 3 principal axes of item
• System-specific tailored test requiring approval from NAVSEA 05P3– Alternative to Heavyweight Test (i.e., “Barge Test”) of MIL-S-901– Input levels tuned to actual field measurements
Hazard Assessment Testing of the SM-3 Block IA Missile
Near Miss Shock Test Setup
Pendulum
Transfer Beam Assembly
Carriage
Encanistered Missile
VLS Dog-Down Fixture
SpringsBrakes
Cradle
Deck Interface Simulator Fixture
Hazard Assessment Testing of the SM-3 Block IA Missile
Tuning of Input for Near Miss Shock Test
Input
LongitudinalComponent
TransverseComponent X - Component
Y - Component
TransverseComponent
Clocking Angle
Obliquity Angle
Pendulum drop height – peak velocityProgrammer pad thickness – initial accelerationBrakes & Springs – initial pulse duration; magnitude of neg. velocityObliquity/clocking – Longitudinal and Transverse components
Hazard Assessment Testing of the SM-3 Block IA Missile
Representative Response Data
RequirementAccelerometer 1Accelerometer 2Accelerometer 3Accelerometer 4Accelerometer 5
Hazard Assessment Testing of the SM-3 Block IA Missile
Configuration of Kinetic Warhead
• 3 propellant grains in Solid Divert and Attitude Control System (SDACS)– Pulse I grain is TP-H-3510 propellant– Pulse 2 grain is TP-H-3511 propellant– Sustain grain is TP-H-3512 propellant
• SDACS case is graphite-epoxy composite
MTA ThrustersSustain Grain
Pulse 1 Grain
Pulse 2 Grain
Guidance Unit
Ejector Assembly
Cryogenic Gas Bottle(Nitrogen @ 6000 psi)
Hazard Assessment Testing of the SM-3 Block IA Missile
Configuration of Kinetic Warhead for Insensitive Munitions Tests
• Kinetic Warhead assembled to simulated Guidance Section shroud– 13.625-in OD annular aluminum cylinder with ½-in thick aluminum closure
plate– Guidance Unit simulated using high-fidelity mass model– Cryogenic gas bottle present and fully-charged
• Block IA Nosecone installed over Kinetic Warhead– Secured to simulated Guidance Section shroud in same manner as
tactical missile– All Nosecone explosive components present
Nosecone
SDACS
Nosecone
End Cap(simulated Guidance Section)
X-SMDC
Cryogenic Gas Bottle
Guidance UnitEjector
Nosecone
SDACS
Nosecone
End Cap(simulated Guidance Section)
X-SMDC
Cryogenic Gas Bottle
Guidance UnitEjector
Hazard Assessment Testing of the SM-3 Block IA Missile
General Configuration of Third Stage Rocket Motor
• 2 propellant grains– Pulse I grain is TP-H-3518A propellant– Pulse 2 grain is TP-H-3518B propellant
• Case sidewall is filament-wound graphite-epoxy composite• Toroidal cold gas bottle contains pressurized nitrogen
Composite Case
Toroidal ColdGas Bottle
Pulse 1 Grain
Pulse 2 GrainIgnition Tube
Hazard Assessment Testing of the SM-3 Block IA Missile
Configuration of Third Stage Rocket Motor for Insensitive Munitions Tests
• TSRM assembled with end caps to simulate adjoining missile sections– Each end cap is 13.72-in OD annular aluminum cylinder with ½-in thick
closure plate– Aft end cap secured using 4 explosive bolts
• Replicate configuration of tactical missile
Hazard Assessment Testing of the SM-3 Block IA Missile
Bullet Impact Test Method• Item impacted by three (max) 0.50-cal AP projectiles
– Velocity of 2800 ± 200 ft/s– Bullets fired at 50 ms intervals using three 50-cal Mann barrels
• Trajectory of bullets perpendicular to longitudinal axis of test item– Bullets aimed to pass through center of SDACS propellant in KW– Bullets aimed to pass through Pulse II grain and ignition tube in TSRM
• Instrumentation and data collection IAW MIL-STD-2105B– Gun firing times– Bullet velocities– Air shock– High-speed video record of events– Post-test recovery and characterization of remains
Hazard Assessment Testing of the SM-3 Block IA Missile
Bullet Impact Test Setup
Hazard Assessment Testing of the SM-3 Block IA Missile
Fragment Impact Test Method• Item impacted by three ½-in mild-steel cubes
– Velocity of 6000 ± 200 ft/s– Cubes launched using 60mm smoothbore gun and unique FRP sabot
• Trajectory of cubes perpendicular to longitudinal axis of test item– Aimed to pass through center of SDACS propellant in KW– Aimed to pass through Pulse II grain and ignition tube in TSRM
• Instrumentation and data collection IAW MIL-STD-2105B– Cube velocities– Air shock– High-speed video record of events– Post-test recovery and characterization of remains
Hazard Assessment Testing of the SM-3 Block IA Missile
Fragment Impact Test Setup
PressureGauge 1
PressureGauge 2
PressureGauge 3
PressureGauge 4
15' R
90°
PressureGauge 5
PressureGauge 6
34' R
Plan View
Velocity Screens (3)
Test Item(assembled in test fixture)
FragmentShield60mm Gun
~7'
~25'~4.5' ~4.5'
Forward End
22' R
Hazard Assessment Testing of the SM-3 Block IA Missile
Fast Cook-Off Test Method• Item suspended above pool of burning JP-5 aviation fuel
– Average flame temperature >1600F– 30-ft x 30-ft fuel basin used to ensure complete immersion within flame
• Instrumentation and data collection IAW MIL-STD-2105B– Flame temperature– Air shock– Video record of events– Post-test recovery and characterization of remains
• Pretest modeling to predict time to reaction– 1-D model to examine radial heat transfer through case sidewall– Examined two bounding flame temperature conditions
• 1600°F average flame temperature• 2000°F average flame temperature
Hazard Assessment Testing of the SM-3 Block IA Missile
Fast Cook-Off Test Setup
Hazard Assessment Testing of the SM-3 Block IA Missile
ReactionsObserved
Predicted Temperature at Liner/Propellant Interface During TSRM Fast Cook-Off
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
0 1 2 3 4 5 6 7 8 9 10 11 12
Time (minutes)
Tem
pera
ture
(deg
F)
1600°F Avg Flame Temp2000°F Avg Flame Temp
FireBuild-Up
AblativeBurn-Off
Predicted Time of Propellant Ignition
Hazard Assessment Testing of the SM-3 Block IA Missile
Summary of Test Results
Third Stage Rocket Motor: Type IV reaction (deflagration)Fast Cook-Off
Kinetic Warhead: Type IV reaction (deflagration)Third Stage Rocket Motor: Type III reaction (explosion)
Fragment Impact
Kinetic Warhead: Type IV reaction (deflagration)Third Stage Rocket Motor: Type III reaction (explosion)
Bullet Impact
No safety-related anomaliesNear Miss Shock
No safety-related anomalies4-Day Temperature & Humidity
No safety-related anomaliesShipboard Vibration
No safety-related anomaliesTransportation Vibration
No safety-related anomalies28-Day Temperature & Humidity
ResultTest
Hazard Assessment Testing of the SM-3 Block IA Missile
Lessons Learned• Multi-shaker setup used for Transportation Vibration test introduces additional
issues related to phase control– Currently not explicitly addressed in MIL-STD-810– Accepted / best practices still evolving
• Not possible to achieve same input levels at both ends of canister in Shipboard Vibration test due to fixture dynamics– Fact-of-life constraint for single-shaker setup using large, complex fixture– Problem most pronounced at higher frequencies– New state-of-the-art facility at NSWC/Dahlgren will enable multi-shaker
testing in vertical orientation• Near Miss Shock test demonstrated capability to replicate real-world triaxial
shock input to large encanistered missile using pendulum-type shock machine– Potential alternative to “Barge Test” for some systems
• Subject to approval by NAVSEA 05P5 on case-by-case basis• May reduce system design risks
Hazard Assessment Testing of the SM-3 Block IA Missile
More Info• Test program documented in two NSWCDD technical reports
– NSWCDD/TR-06/47, Standard Missile - 3 Block IA Hazard Assessment Test Results
• Draft currently in final review– NSWCDD/TR-06/48, Standard Missile-3 Block IA Near Miss Shock
Qualification Test Report