RDECOM ALR Program Lead-Free, DBX-1 Projects · 8/30/2016 · DBX-1 - different particle sizes will help meet performance requirements for diverse component sizes of detonators,

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Distribution A: Approved for Public Release. Distribution is Unlimited.

RDECOM ALR Program

Lead-Free, DBX-1 Projects

Neha Mehta

Oct 2016

1

Unclassified


Neha Mehta

Technical Lead, Chemical Engineer

Explosives Development Branch

973-724-2912

[email protected]

Airborne Lead Reduction IPR

Qualification of Green Primary Explosive,

DBX-1 (ALR 14-01)

08/30/2016

Unclassified-Distribution A

Distribution A: Approved for Public

Release. Distribution is Unlimited 3

Qualification of Green Primary Explosive,

DBX-1 (ALR 14-01)

Project Description

ARDEC will qualify Copper (I) 5-

Nitrotetrazolate (DBX-1) at 500-gram scale to

Army performance requirements

Replace lead azide and lead styphnate in

detonators, some primers, blasting caps, etc.

(studies already completed at lab scale)

Produce and qualify green NOL-130 (stab

mix) for detonators

Transition to field through SWO-10

Requirement/Impact

Addresses AERTA PP-12-09-02 by qualifying

a lead-free primary explosive for Army use

Until DBX-1 is qualified, there are no Army

qualified primary explosive alternatives to lead

based compounds in detonators, primers, etc.

NAS study on lead exposure on firing ranges

finds current occupational exposure level in

not protective of soldiers/workers on ranges.

M115 Primer 25mm Round

Progress ReportKey dates

Endorsement signed by PEO-AMMO: 3Q-FY13

TTA signed by PM-CCS: 4Q-FY16

End/transition point: 3Q-FY16

Recent accomplishments/issues

12 month aging completed

All results compare to PSEMC batch

Working on final qualification report



Release. Distribution is Unlimited

What is the intended end product? Qualify DBX-1 as an Army primary explosive as a replacement of lead azide,

lead styphnate and DXN-1 Established process to make more environmentally sustainable stab mix

qualified for use in the Army Transition upon approval by Army Energetic Material Qualification (EMQ)

Board, incorporate DBX-1 into SWO-10

What is the technical approach? Perform testing according to Army EMQ matrix with 12 months aging PSEMC produce 5-100 grams batches of DBX-1 blended to one lot Load M55 Detonators with DBX-1 as transfer charge and green stab mix at DZI Complete First Article Testing DBX-1 not currently qualified to Army requirements PHC completed Toxicology Assessment of DBX-1 (leverage ESTCP)

What specific weapon system applications will the product transition to? Stab detonators (M55, M98, M61) Primers (#41, M42, M115) Blasting Caps (M6, M7, M11) APOBS Hand Grenade Fuze Detonator

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Project Description (ALR-14-01)




What performance, regulatory and other drivers is the project addressing?

Addresses AERTA PP-12-09-02 by qualifying a lead-free primary explosive for

Army use

Revision to lead NAAQS for airborne lead

NAS study on lead exposure on firing ranges finds current occupational

exposure level is not protective of soldiers/workers on ranges

What are the impacts and benefits of the project?

ESOH: Reduce lead from the environment and lead exposure for

soldiers/workers in potentially 1000s of items

Economic: Title III Defense Production Act (OSD) office is investing in

producing DBX-1 at larger scale, work will start FY16 onwards. Once

qualification is complete, material produced through the Title III effort will be

used to test in items. Anticipate production costs same as lead azide

($700/lb); reduction in cost of more than 50%.

Scientific: Industry has approved use of DBX-1 but not yet approved to Army

requirements. Lead-free primers in industry do not meet Army performance

requirements.

Other: Potential range restrictions if firing ranges are not compliant with

occupational exposure levels or if occupational exposure level are reduced.

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Requirement/Impact (ALR-14-01)

Unclassified


Neha Mehta



973-724-2912

[email protected]


Continuous Process to Produce NaNT/DBX-1

(ALR 13-02)

08/30/2016

Andrew Pearsall/Jerry Salan

Nalas Engineering




Continuous Process to Produce

NaNT/DBX-1 (ALR 13-02)

Project DescriptionARDEC/Nalas Engineering will develop one-

pot, high yielding, safe process to produce

NaNT (for production of DBX-1)

Develop kinetic model for the synthesis of

NaNT (Nalas Engineering) to understand the

reaction kinetics to determine process variables

that avoid hazardous conditions and impurities

From one-pot process directly convert the

crude NaNT solution to make DBX-1

Transition process specification to manufacturer

Requirement/Impact

Addresses AERTA PP-12-09-02 by

developing a large-scale production process

for a lead-free primary explosive: DBX-1

Current production processes can not meet

Army production requirements. Continuous

process will increase throughput and reduce

worker exposure to sensitive materials.

DBX-1 could be used in 1000s of systems

Progress ReportKey dates





Nalas Engineering received and installed the 5-

L reactor with the sampling system – Dec 2014

Produced 3 batches of NaNT successfully

DBX-1 produced successfully from NaNT

Design and Testing of 20-L reactor completed

2 out of 3 batch produced and were successful

Lean Process to Produce NaNT/DBX-1

NaNT Manufacture




What is the intended end product? Develop a one-pot, high yield and safe process to make NaNT and

integrate the process to produce DBX-1 Process specification will be transitioned to proposed manufacturer

What is the technical approach? The current synthetic process for NaNT can not be scaled further since

there are issues with unsafe micro-detonations during the process and also requires further purification through a controlled laboratory titration

Design a remote, scalable process that produces high quality NaNT Fabricate a 20L reactor suitable for “one-pot” NaNT process Demonstrate that NaNT produced is suitable for DBX-1 process

What specific weapon system applications will the product transition to? 1000s of items use lead based primary explosives Stab detonators (M55, M98, M61) Primers (#41, M42, M115) Blasting Caps (M6, M7, M11)

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Project Description (ALR-13-02)




What performance, regulatory and other drivers is the project addressing?

Addresses AERTA PP-12-09-02 by developing a large-scale production process for a lead-free

primary explosive: DBX-1

Need a scalable, safe process to make NaNT, as it is the precursor for DBX-1

NAS study on lead exposure on firing ranges finds current occupational exposure level is not

protective of soldiers/workers on ranges

What are the impacts and benefits of the project?

ESOH: Reduce lead from the environment and lead exposure for soldiers/workers. Using DBX-1 as

LA replacement, DoD will save cost and simultaneously be in compliance with executive orders

requiring the replacement of toxic materials. It will also enable DoD to reduce lead exposure on

firing ranges and shoot houses.

Economic: Eliminated ~30% labor (e.g. titration, isolating NaNT solids) and ~25% material costs

(e.g. titration, waste). Eliminated NaNT solution storage costs (e.g. just in time manufacturing).

Title III OSD office is investing in producing DBX-1 at larger scale, work will start FY17

onwards. This would benefit to have a one-pot process and not delay in the production. This

will bring cost of DBX-1 to same or lower than lead azide, $700/lb.

Scientific: This process consists of fewer steps and is a continuous and one pot process instead of

tedious unsafe process initially developed.

Other: The current process has challenges with unsafe micro-detonations during the process and

requires further purification to afford DBX-1. Need a high yield one pot process to make NaNT.

This will reduce worker exposure to material as the current process requires manual separation.

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Requirement/Impact (ALR 13-02)

Unclassified


Neha Mehta



973-724-2912

[email protected]


DBX-1 Particle Size Characterization (ALR 15-01)

08/30/2016 Jerry Salan

David Ford

Daving Piercey

Nalas Engineering




DBX-1 Particle Size Characterization

(ALR 15-01)

Project Description

ARDEC and Nalas Engineering will develop a

process to produce different particle size of

copper(I) 5-nitrotetrazolate (DBX-1), similar to RDX

and HMX, for different applications

Having different particle size of DBX-1 will benefit

all items such as primers, detonators, blasting caps

Optimize process parameters, categorize particle

size distributions and test in different items

Process specifications transition to manufacturer

selected in Title III DPA project

Requirement/Impact

Addresses AERTA PP-12-09-02 by developing

new particle sizes for lead-free primary explosive

Although a viable candidate for a drop-in

replacement has been identified in DBX-1,

transition towards commercialization is hindered

by particle size distribution and ability to load the

material in various units

Particles sizes increase packing fraction and

number of potential applications for DBX-1

Progress Report

Key dates





Working with different process to achieve

different particle size




What is the intended end product? A controlled process will be specified to formulate different particle sizes of

DBX-1 - different particle sizes will help meet performance requirements for diverse component sizes of detonators, primers, initiators, etc.

Standardized process will transition to manufacturing partners

What is the technical approach? Leverage prior experience in optimizing NaNT/DBX-1 process to understand

the effect of impeller speed and geometry on DBX-1 particle size

Modeling software will be used to design a series of scaled-down

experiments in which mixing parameters and resulting influence on particle

size will be examined.

Study the effect of seed type on final crystal form (i.e., agglomerated vs.

single crystal). Other parameters such as reaction time, concentration will

be evaluated.

What specific weapon system applications will the product transition to? All items that are proposing to use DBX-1, which includes

Stab detonators (M55, M98, M61)

Electric Detonators (M100)

Primers (#41, M42, M115)

Blasting Caps (M6, M7, M11)

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Project Description (ALR 15-01)




What performance, regulatory and other drivers is the project addressing? Addresses AERTA PP-12-09-02 by increasing potential applications for lead-free primary

explosive (DBX-1) Scaling up DBX-1 requires utilization of larger equipment. Crystallizations do not scale-up

predictably; mass transfer and mixing depend on the equipment geometry and its configuration. The existing particle size distribution (PSD) is not ideal for all potential applications using DBX-1.

Revision to lead NAAQS for airborne lead NAS study on lead exposure on firing ranges finds current occupational exposure level is

not protective of soldiers/workers on ranges

What are the impacts and benefits of the project? ESOH: Reduce lead in up to 1000s of weapon systems and lead exposure for

soldiers/workers Economic: There would be no extra cost associated with producing different particle size

as it would be part of the process. This project will save cost from milling to smaller size when needed for electric detonator to replace lead styphnate spot charge.

Scientific: Current processes produce single particle size DBX-1. Process characterization is needed to consistently produce multi-particle size DBX-1 for a variety of Army applications. This new process can be applied to other material production processes.

Other: Transition towards commercialization is hindered by particle size distribution and ability to load the material in various units. Different particle size can effect the performance and loading ability. Having different classes of DBX-1 and identifying the process would employ consistent material process and performance.

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Requirement/Impact (ALR-15-01)

Unclassified


Neha Mehta



973-724-2912

[email protected]


Green Improved Process to Load Primers

(ALR 14-02) 08/30/2016

Matthew Puszynski

Zac Doorenbos

Innovative Materials and Processes, LLC




Green Improved Process to Load Primers

(ALR 14-02)

Project Description

ARDEC and Innovative Materials and

Processes, LLC (IMP) will develop an

automated loading process for lead-free

primer formulations.

Develop DBX-1 based formulation for potential

use in percussion primer.

Leverage prior research in primer loading

technologies to apply to DBX-1 based

formulations.

Requirement/Impact

Addresses AERTA PP-12-09-02 by developing a process to produce lead-free primers -currently all the primers are based on lead styphnate.

New, automated loading process will reduce operator error (reducing malfunction) and increase # of primers produced per shift/year.

Process will reduce worker exposure to hazardous and very sensitive explosives.

Progress Report

Key Dates:




Recent accomplishments/issuesSolvent and binder selected;

DBX-1 based primer formulation selected;

Slurry loading of M42 primers demonstrated.

Current

Manual Process

Future Automated

Dispensing Process




What is the intended end product? Automated loading process for lead-free primer formulations. Transition to GOCO plants such as LCAAP for loading primers as

part of modernization.

What is the technical approach? ARDEC, with EQT P2 support, developed a new DBX-1 based

formulation for potential use in percussion primers. Leverage Innovative Materials and Processes (IMP) automated

loading process core technology developed under Army and Navy SBIR programs (can be applied to process sensitive energetic mixtures, which require precise dosing into applications).

Evaluate automated system for very precise, remote, reliable and repeatable dosing of lead-free primer mixtures.

What specific weapon system applications will the product transition to? Primers (#41, M42, #34, #50M, M115)

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What performance, regulatory and other drivers is the project addressing? Addresses AERTA PP-12-09-02 by developing a process to produce lead-free primers

Currently all the primers are based on lead styphnate Revision to lead NAAQS Multiple federal environmental regulations NAS study on lead exposure on firing ranges.

What are the impacts and benefits of the project? ESOH: Reduce operator exposure to lead-based primary exposure and breathing of

solvent vapors. Reduction in hazardous waste. Also, reduction of dusting via proper binder control

Economic: New automated loading process will reduce operator error (reducing malfunction) and increase # of primers produced per shift/year. Anticipated primer loading will be less expensive using this process.

Scientific: State of the art uses manual loading processes. Automated processes have been developed for alternative primer formulations; however, they have not been optimized for DBX-1 formulation. Controlled Process – Producibility will increase 100% as material will be homogeneous and loading will be done with accuracy.

Other: Currently two operators can load 3600 primers in one shift (918,000 primers/year). Depending on the # of stations set up, this can be automated process and can make over 100,000 in one shift. There is only one processing method to make primers and is dependent on operators and conditions. This would eliminate the operator dependent process.

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Unclassified


Neha Mehta



973-724-2912

[email protected]


Detonator Demonstration (ALR 15-02)

08/30/2016




Detonator Demonstration (ALR 15-02)

Project Description

ARDEC will demonstrate DBX-1 as a

replacement for lead azide and lead styphnate

in:

Detonators for projectile/mortar fuzes

Detonators for hand grenade fuzes

Blasting caps

Leverage prior formulation efforts in EQT

program

Requirement/Impact

Addresses AERTA PP-12-09-02 by replacing lead based primary explosives with DBX-1 in detonators and blasting caps

Reduce lead styphnate and lead azide with one material

Loading process will reduce worker exposure to hazardous and very sensitive explosives

Progress ReportKey Dates


TTA signed by PEO Ammo: 4Q-FY16



M100 electric detonator: 100+ spot charged

with DBX-1 and transfer charge as DBX-1, all

successful fired – LAT completed and

successful

C70 detonator: In-house testing successful




What is the intended end product? DBX-1 demonstrated as a viable lead azide and lead styphnate

alternative for lead-free Detonators, Blasting Caps for mortars, projectile and grenade fuzes

What is the technical approach? ARDEC, with EQT support, have tested DBX-1 as lead azide

replacement in stab and electric detonators Load M55 and M100 electric detonators with DBX-1, lead-free material

and evaluate the performance and compare to standard detonators Perform LAT and performance testing with Lead/booster output test Perform dent depth testing for detonators and blasting caps and

compare

What specific weapon system applications will the product transition to? Mortars Fuzes Projectile Fuzes Hand Grenade Fuzes Blasting Caps – M6, M7, etc.

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What performance, regulatory and other drivers is the project

addressing? Addresses AERTA PP-12-09-02 by developing lead-free end items

Currently all the detonators, blasting caps are based on lead styphnate/lead azide

Revision to lead NAAQS Multiple federal environmental regulations NAS study on lead exposure on firing ranges shows that current OEL

is not protective of workers and soldiers on firing ranges.

What are the impacts and benefits of the project? ESOH: Reduce operator exposure to lead-based primary exposure

and breathing of solvent vapors. Reduction in hazardous waste. Economic: DBX-1 works as lead azide and lead styphnate replacing

in many detonators and primers. When replacing lead material with DBX-1, usually requires 30-40% less material due to its density and performance output.

Scientific: There will be only one replacement for both material and will avoid separation and loading issues.

Other: Current mix is not government owned TDP

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Documents

RDECOM ALR Program Lead-Free, DBX-1 Projects · 8/30/2016 · DBX-1 - different particle sizes will help meet performance requirements for diverse component sizes of detonators,