TACOM Tank-automotive & Armaments COMmand Presented by: Leslie Fishbein Armament Systems Process Division WECAC Rheological Capabilities at TACOM-ARDEC

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TTank-automotive & AArmaments COMCOMmand

Presented by:Presented by:

Leslie FishbeinLeslie FishbeinArmament Systems Process DivisionArmament Systems Process Division

WECACWECAC

Rheological Capabilities at Rheological Capabilities at TACOM-ARDECTACOM-ARDEC

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PurposePurpose

Provide an overview of efforts to establish a state-of-the-art energetic materials characterization

laboratory at TACOM-ARDEC

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OutlineOutline

Mission

Equipment Capabilities

Future Work

Summary

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The TACOM-ARDEC MissionThe TACOM-ARDEC Mission

The Rheology Laboratory will enhance TACOM-ARDEC’s role as a leading developer of new energetic compositions and processes:• FCS propellants in support of the Multi-role Armament and

Ammunition System (MRAAS)• State-of-the-art processing of energetic materials at the Building

1403 Twin-Screw Mixer/Extruder• Process modeling and simulation• Support of items in production (e.g., M30A1, JA-2, AA-2, PAP-

7993, M14, Ball Powders)

Opportunities to team with Industry and Academia:• Stevens Institute of Technology (SIT)• Polymer Processing Institute, New Jersey Institute of Technology

(NJIT)• ATK/Radford AAP• GENCORP Aerojet• ATK/Thiokol Propulsion

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The Rheological LaboratoryThe Rheological Laboratory

• Consolidate rheological capabilities under one roof: Remotely operated systems User friendly software for data acquisition and analysis

• Support TACOM-ARDEC material characterizations: Energetic materials (Propellants, Explosives, Pyrotechnics) Precursor Materials (e.g., ETPEs, binders) Plastics Epoxies Composites Resins

• Support process modeling and simulation efforts: Twin-Screw Mixer/Extruder Shear Roll Mill Cryogenic Polymerization Reactor

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Capillary RheometerCapillary Rheometer

Instron Load Frame Model #5581 and

Shear Tool Capillary Adapter Assembly

• Similar to laboratory-scale extruder that is highly instrumented and accurately controlled

• Relate changes in processing conditions (pressure, temperature) of extrusion to product properties (mechanical, ballistic)

• Characterize the rheological/flow properties of energetic materials under different conditions (temperature, composition)

• Obtain a constitutive equation for the energetic materials for process analysis and simulation using RheoPlotter software

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Apply Different Speeds (S) at controlled Temperature

Obtain Forces (Resistance to Flow)

Data Analysis

Viscosity = F (shear rate, temperature)

Relate To

Die Forming Flow in Processing Equipment

Reservoir

Capillary

Plunger

S~

• To determine the rheological properties as a function of shear rate, temperature, pressure, and molecular weight, which is crucial to the design and control of process operation

Capillary RheometerCapillary Rheometer

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Rheometric Scientific Dynamic Analyzer- RDA III

• Study the dynamic mechanical properties of the energetic materials (G, G, tan )

• Study the complex viscosity (*) and viscoelastic behavior

• Investigate the molecular structure and interaction/compatibility between the ingredients of the energetic materials

• Study the reaction kinetics of reactive system

Rotational RheometerRotational Rheometer

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Apply Strain A=A0sint

Measure Torque, Normal Force

Apply Strain A=A0sint where A0: small amplitude

Obtain Normal Force, TorqueTorque = T sin t + T cos t

Data Analysis

Relate To

Elastic Properties

Viscous Properties

“Structure” of the Mixture (MW, concentration, degree of mixing,

compatibility, crosslinking)

Rotational RheometerRotational Rheometer

• Measures viscosity, elasticity and shear modulus

• Can perform controlled strain, stress and strain rate experiments

• Includes range of test fixtures: Parallel plate Torsion fixtures

• Allows for characterization from: Suspensions,

emulsions, Polymer melts,

elastomers Solids

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The Poly Lab 300p enables production of small batches with simultaneous recording of torque and time while mixing material:• High torque capability • Oil heated and cooled chamber and plates• Rotors for different shear ranges:

Roller blades (viscous properties for thermoplastics & thermosets) Cam blades (thermoplasts & elastomers in medium shearing range) Banbury blades (natural and synthetic rubber) Sigma blades (low shear ranges; most suitable f/energetic

materials)• Teflon bushings to test chemically aggressive media• Special tools to clean the mixer parts• Pneumatic ram • Poly View data evaluation; i.e.:

Routine evaluation --Rheograms (torque vs. time) Multi curve Analysis

Torque RheometerTorque Rheometer

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Torque RheometerTorque Rheometer

• The torque rheometer is capable of the measuring the following: Dynamic viscosity depending on shear load Melt behavior in the extruder The influence of additives Temperature and shear load behavior

• TACOM-ARDEC will mainly be using Rheometer for it’s mixing capabilities

Thermo Haake Poly-Lab 300p System

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Internal Mixer Torque RheometerInternal Mixer Torque Rheometer

Apply rpm () = Constantat Controlled Temperature

Obtain Torque (time)

Data Analysis

Specific Energy Requirement for Mixing, Reaction = F (time)

Relate To

Mixing, Reaction = F (axial distance)in an extruder

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Planned Work Loading – FY 03Planned Work Loading – FY 03

Army• Characterization of JA-2 and AA-2 propellant produced on a Shear

Roll Mill (ManTech)

Supports modeling activity w/SIT

Leveraged with implementation of SRM technology in support of the manufacture of solventless propellants at Radford AAP

• Characterization of ETPEs (ManTech)

Supports TACOM-ARDEC modeling activity and ETPE process optimization

• Begin developing of rheological data base for energetic materials consider for TSE processing (ManTech) Propellants (e.g., M39 / M43 LOVA) Explosives (e.g., PAX-2A IM) Pyrotechnics (e.g, M206, MJU-7A/B, MJU-53/B)

• 155-mm M485 Illumination Round Characterization of replacement material for liquid polysulfide

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Planned Work Loading InitiativesPlanned Work Loading Initiatives

Potential (3rd party)

• ATK / Radford AAP (gun propellants):

Full-time PhD Rheologist -- no laboratory capability

• ATK / Thiokol Propulsion (rocket and gun propellants)

• GENCORP Aerojet (CRADA tasking)

• BAE Systems / Holston AAP (explosives)

• SIT (in support of process modeling)

• PPI, NJIT (CRADA):

Expand PPI commercial market place through use of Rheology Laboratory at TACOM-ARDEC

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SummarySummary

• Rheology Lab is in full operational status

• The characterization of Energetics is to be used to understand, simulate, design, and optimize the manufacturing processes

• CRADA has been signed with PPI/NJIT

• Future work is being discussed with SIT, ATK, and Aerojet

• Questions and Inquires to be addressed to:

Lilia Mastov

TACOM-ARDEC

(973)724-3351

[email protected]

Documents

TACOM Tank-automotive & Armaments COMmand Presented by: Leslie Fishbein Armament Systems Process Division WECAC Rheological Capabilities at TACOM-ARDEC