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Final Technical Report Lead Free Electric Primer Final Technical Report Lead Free Electric Primer (SERDP Project WP-1331) Naval Air Warfare Center, Weapons Division Robert Brewer, Phil Dixon, Sarah Ford, Kelvin Higa, Ron Jones Code 478000D (Mail Stop 5400) 2400 E Pilot Plant Road China Lake, CA 93555-6107 Approved for public release; distribution is unlimited. Form Approved REPORT DOCUMENTATION PAGE OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202- 4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 1. REPORT DATE (DD-MM-YYYY) 2. REPORT TYPE 3. DATES COVERED (From - To) 06-10-2011 Final Feb. 2004 - Dec. 2006 4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER LEAD -FREE ELECTRIC PRIMER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER Robert Brewer, Phil Dixon, Sarah Ford, Kelvin Higa, Ron Jones WP-1331 5e. TASK NUMBER NA 5f. WORK UNIT NUMBER NA 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT Naval Air Warfare Center, Weapons Division NUMBER Code 478000D (mail Stop 5400) 2400 E. Pilot Plant Road NA China Lake, CA 93555-6107 9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S) Weapons Systems & Platforms SERDP SERDP and ESTCP Program Offices 901 N. Stuart Street, Suite 303 11. SPONSOR/MONITOR’S REPORT NUMBER(S) Arlington, VA 22203-1853 12. DISTRIBUTION / AVAILABILITY STATEMENT Approved for Public Release: Distribution is unlimited 13. SUPPLEMENTARY NOTES 14. ABSTRACT NAWCWD overcame some major obstacles, meeting both the low-temperature firing requirement (-65°F) and AUR action time (less than 4ms). Many reformulations were required to optimize the LFEP composite. To date there has not been a single incident with the current aluminum/molybdenum formulation. This demonstrates that the LFEP can be used with suitable safety guidelines. The final formulation consisted of 76% Al(50nm)/MoO3(45nm), 20% BTATZ, 2% Kel-F, and 2% Carbon Black. A critical parameter for nano aluminum powder stability in air was a passivation oxide thickness of at least 2.7 nm. Al powders with thinner oxide layers aged badly resulting in poor primer performance. 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION 18. NUMBER 19a. NAME OF RESPONSIBLE PERSON U OF ABSTRACT OF PAGES Kelvin Higa a. REPORT b. ABSTRACT c. THIS PAGE UU 19b. TELEPHONE NUMBER (include area code) U U U 96 (760) 939-1656 Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std. Z39.18 CONTENTS Acronyms ........................................................................................................................................ 4 Executive Summary ........................................................................................................................ 6 Objective ......................................................................................................................................... 7 Background ..................................................................................................................................... 7 SEED Program .........................................................................................................................7 Follow-On Program ..................................................................................................................9 Materials and Methods .................................................................................................................. 10 Technical Approach................................................................................................................10 Materials Characterization ......................................................................................................10 Formulation ............................................................................................................................11 Safety Characterization ..........................................................................................................11 Human-Body Static Energy ........................................................................................... 12 Production Methods................................................................................................................13 AUR Test Setup ......................................................................................................................13 Accomplishments .......................................................................................................................... 15 Materials Characterization ......................................................................................................15 Aluminum ...................................................................................................................... 15 Molybdenum Trioxide ................................................................................................... 18 Bismuth .......................................................................................................................... 21 Metastable Interstitial Composite (MIC) ....................................................................... 21 Formulation ............................................................................................................................22 Alternative Oxidizers..............................................................................................................29 Safety Characterization ..........................................................................................................31 Handling Safety.............................................................................................................. 34 Production Methods................................................................................................................40 Mixing ............................................................................................................................ 40 Loading .......................................................................................................................... 46 Solvent-Based Loading .................................................................................................. 46 Puszynski Method .......................................................................................................... 49 Solvent-Based Method Optimized ................................................................................. 51 Production Processes...................................................................................................... 52 AUR Results ...........................................................................................................................52 Partnering ...................................................................................................................................... 57 Collaboration/On-Site Training ..............................................................................................58 Summary and Conclusions ........................................................................................................... 63 1 Figures Figure 1 – Conventional Primer Configuration .............................................................................. 8 Figure 2 – Exploding Foil Primer Configuration ............................................................................ 9 Figure 3 – ESD Test Apparatus .................................................................................................... 12 Figure 4 – Cold-Temperature Test Shroud ................................................................................... 15 Figure 5 – SEM Photographs of MoO3 Morphology .................................................................... 20 Figure 6 – Scanning Electron Micrographs of Bi2O3 From Different Vendors ............................ 21 Figure 7 – Bismuth (III) Oxide Ignition Testing .......................................................................... 25 Figure 8 – Pressure Cell Versus Pan Dent Optimization .............................................................. 27 Figure 9 – Pan Dent Optimization of Al (50 nm)/MoO3 Composite ............................................ 28 Figure 10 – Ignition of I2O5 On Aluminum Pan ........................................................................... 29 Figure 11 – Percentage of Primers Fired Versus Voltage ............................................................. 34 Figure 12 – Maximum Pressure Versus Gas Additive.................................................................. 44 Figure 13 – Pressurization Rate Versus Gas Additive .................................................................. 44 Figure 14 – MIC Pressing Operation ...........................................................................................
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