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Unclassified RDECOM ALR Program Lead-Free, DBX-1 Projects Neha Mehta Oct 2016 Distribution A: Approved for Public Release. Distribution is Unlimited. 1 Unclassified Airborne Lead Reduction IPR Qualification of Green Primary Explosive,

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SLIDE 1

Unclassified

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

RDECOM ALR Program Lead-Free, DBX-1 Projects

Neha Mehta Oct 2016

1

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SLIDE 2

Unclassified

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

Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil

Airborne Lead Reduction IPR Qualification of Green Primary Explosive, DBX-1 (ALR 14-01)

08/30/2016

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited

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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 Report

  • Key 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
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Unclassified-Distribution A

Distribution A: Approved for Public

  • 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)

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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
  • ccupational exposure levels or if occupational exposure level are reduced.

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Requirement/Impact (ALR-14-01)

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Unclassified

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

Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil

Airborne Lead Reduction IPR Continuous Process to Produce NaNT/DBX-1 (ALR 13-02)

08/30/2016

Andrew Pearsall/Jerry Salan Nalas Engineering

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited

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Continuous Process to Produce NaNT/DBX-1 (ALR 13-02)

Project Description

  • ARDEC/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 Report

  • Key dates
  • Endorsement signed by PEO-AMMO: 3Q-FY13
  • TTA signed by PM-CCS: 4Q-FY16
  • End/transition point: 1Q-FY17
  • Recent accomplishments/issues
  • 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

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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)

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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
  • nwards. 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)

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Unclassified

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

Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil

Airborne Lead Reduction IPR DBX-1 Particle Size Characterization (ALR 15-01)

08/30/2016

Jerry Salan David Ford Daving Piercey Nalas Engineering

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited

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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
  • Endorsement signed by PEO-AMMO: 3Q-FY13
  • TTA signed by PM-CCS: 4Q-FY16
  • End/transition point: 1Q-FY17
  • Recent accomplishments/issues
  • Working with different process to achieve

different particle size

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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)

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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)

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Unclassified

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

Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil

Airborne Lead Reduction IPR Green Improved Process to Load Primers (ALR 14-02)

08/30/2016

Matthew Puszynski Zac Doorenbos Innovative Materials and Processes, LLC

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited

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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
  • perator 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:
  • Endorsement signed by PEO-AMMO: 3Q-FY13
  • TTA signed by PM-CCS: 4Q-FY16
  • End/transition point: 4Q-FY18
  • Recent accomplishments/issues
  • Solvent and binder selected;
  • DBX-1 based primer formulation selected;
  • Slurry loading of M42 primers demonstrated.

Current Manual Process Future Automated Dispensing Process

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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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Project Description (ALR 14-02)

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SLIDE 17

Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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

  • ptimized 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

  • perator dependent process.

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Requirement/Impact (ALR 14-02)

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Unclassified

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

Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil

Airborne Lead Reduction IPR Detonator Demonstration (ALR 15-02)

08/30/2016

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited

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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
  • ne material
  • Loading process will reduce worker exposure

to hazardous and very sensitive explosives

Progress Report

  • Key Dates
  • Endorsement signed by PEO-AMMO: 3Q-FY13
  • TTA signed by PEO Ammo: 4Q-FY16
  • End/transition point: 2Q-FY18
  • Recent accomplishments/issues
  • 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
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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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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Project Description (ALR 15-02)

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Unclassified-Distribution A

Distribution A: Approved for Public

  • Release. Distribution is Unlimited
  • 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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Requirement/Impact (ALR 15-02)