Abstract: Non-lethal payloads including at least one of boron and silicon, at least one fuel, and at least one oxidizer. The non-lethal payload may be a single-component or dual-component payload. Methods of producing the non-lethal payloads are also disclosed.

Abstract: This invention relates to the construction of a rocket motor and fuel system thereof and, in particular to a new and useful Viscous Liquid Monopropellant (VLM) rocket motor containing a liquid propellant that is pumped into the combustion chamber, atomized and then ignited. The atomization step significantly increases the surface area of the propellant, delivering faster burn rates and smoother combustion. VLM is a non-Newtonian fluid containing both oxidizers and fuels. These monopropellants are comprised of a variety of liquid and solid components, mixed together to form a homogenous fluid, although heterogeneous in composition. The solid constituents are retained within the liquid phase by dispersion, suspension, bonding or chemical emulsification techniques, so as when a motive force is applied to the propellant, all the constituents are also transported, and held in correct proportion while doing so.

Abstract: The oxygen generation compositions include about 0.5-15% by weight of a substantially carbon-free metal fuel, and about 0.1-20% by weight of alkali metal silicate, stannate, titanate or zirconate as a reaction rate and core rheology modifier and chlorine suppresser. The oxygen generating compositions also contain about 0.1-15% by weight of a transition metal oxide catalyst; and the remainder is substantially an alkali metal chlorate or perchlorate.

Abstract: An energetic solid rocket motor propellant having one or more plateau regions of low operating pressure exponent is disclosed. The propellant is formulated from ingredients including an energetic polyoxetane, an effective amount of a plasticizer, an inorganic oxidizer in at least two discrete particle size ranges, and a refractory oxide burn rate modifier.

Abstract: The invention relates to novel non-detonatable pyrotechnic materials which have a thickness of less than 500 .mu.m or a mass of less than 15 mg, whose combustion is self-sustainable after localized initiation by an electrical power of between 150 mW and 800 mW, for a time of between 20 ms and 600 ms, and which comprise from 25 to 80% by weight of an energy-releasing binder based on poly(glycidyl azide), or on poly(3,3-bis[azidomethyl]oxetane) or on a polyester or polyether and on at least one energy-releasing plasticizer, from 10 to 70% by weight of ammonium perchlorate, the particle size of which is between 0.5 and 30 .mu.m, and from 0% to 45% by weight of at least one nitramine.These novel materials are used as miniature gas generators, miniature propulsion units or miniature heat generators.

Abstract: Tris(N-nitrosophenylhydroxylaminium)aluminum is employed in amounts from about 0.1% by weight to about 0.2% by weight to inhibit the polymerization reaction during propellant mixing. With a weight percent of 0.2 percent, the inhibitor inhibited polymerizaiton to control end-of-mix viscosities to 12 Kp and 13 Kp compared to control propellant viscosities of 26 Kp and 39 Kp after 8 hours and 10 hours respectively. The test propellant and control propellant contained the name ingredients with the exception of the 0.2% additive of the inhibitor in the test propellant. The propellant composition for control and test comprised ammonium perchlorate of 400 micrometer, 200 micrometers, and 20 micrometers in weight percent amounts of 29.5,30.0, and 5.0 respectively, aluminum powder 14.0 weight percent, cyclotetramethylenetetranitramine oxidizer of 4 micrometers particle size in amount of 10.0 weight percent, and hydroxyl-terminated polybutadiene prepolymer binder in a weight percent amount of 11.

Abstract: Mechanical enhancement of the burning rate of solid propellants is achieved y the incorporation of limited percentages of heat-expandable beads into the solid propellant matrix. When the flame front reaches an individual bead, the bead which contains an expanding or blowing agent (e.g., pentane, 4,4'-oxybis(benzenesulfonyl hydrazide) (Celogen OT), etc., expands to several times its volume and ruptures. Bead expansion or rupture causes a disruption of the propellant's surface, and the flame can penetrate into the propellant. This penetration results in a major increase in burning rate.

Abstract: A fast-acting cure catalyst for use in hydroxyl-terminated polybutadiene-ed solid propellant formulation is tris(ethoxyphenyl)bismuthine. The incorporation of this catalyst as an additive in an amount of about 0.025 weight percent into a composite propellant formulation enables the formulation to be ambient mixed and ambient cured at 80.degree. F. or accelerated oven cured at 140.degree. F. Both oven and ambient cures are considerably more cost effective than the conventional oven cure if the prior art cure catalyst, triphenylbismuthine (TPB), is used. Other composite propellant ingredients comprise ammonium perchlorate of about 65 weight percent, aluminum powder of about 14 weight percent, the organic oxidizer, cyclotetramethylenetetranitramine, of about 10 weight percent, isophorone diisocyanate additive to provide an isocyanate/hydroxyl ratio of about 0.92, and hydroxyl-terminated polybutadiene polymer of about 11.5 weight percent.

Abstract: Apparatus for producing a multi-phase emulsion explosive from a liquid organic fuel medium and an immiscible liquid oxidizer comprises a mixing chamber, flow constrictor means for introducing the liquid oxidizer as an emergent turbulent jet to said chamber and causing formation of droplets of said oxidizer in situ within the chamber, means for introducing the fuel medium to said chamber so that the fuel introduced thereby contacts and stabilizes the droplets of oxidizer solution as they are formed to maintain same as discrete droplets of oxidizer liquid and thereby provide an emulsion suitable for use as the basis for an explosive system.

Abstract: Composite solid propellants are provided containing, in an amount effective to reduce the burning rate of the propellant, at least one bitetrazole compound.

Abstract: In emulsion blend explosives, the replacement of coarse salt particles, e.g., prills, by fines, i.e., particles which pass a No. 50 U.S. sieve, increases the water resistance of the explosive without deleteriously affecting its shelf life provided that the explosive, prior to such replacement, is storage-stable as determined by the Salt Extraction and lead compression tests described herein. Products containing a combination of whole and crushed ammonium nitrate prills, and emulsions made with an anionic emulsifying agent such as a fatty acid salt, are preferred. Depending on the fines content and chemical composition, other properties such as sensitivity to initiation and detonation velocity also may be improved.

Abstract: A solid or semisolid propellant comprising grains of propellant or propellant components bonded together so as to create voids within the propellant volume, said grains bonded together with sufficient strength to substantially delay the fluidization of the propellant by the onset of Taylor unstable burning, said propellant having a rapid burn rate below that associated with Taylor unstable burn. In another embodiment, the grains are held within and the voids are filled with viscous fluid binder such as a petroleum oil, said binder functioning to hinder Taylor unsatable burning and yet permit very rapid burning within the propellant volume.

Abstract: In emulsion blend explosives, the replacement of coarse salt particles, e.g., prills, by fines, i.e., particles which pass a No. 50 U.S. sieve, increases the water resistance of the explosive without deleteriously affecting its shelf life provided that the explosive, prior to such replacement, is storage-stable as determined by the Salt Extraction and lead compression tests described herein. Products containing a combination of whole and crushed ammonium nitrate prills, and emulsions made with an anionic emulsifying agent such as a fatty acid salt, are preferred. Depending on the fines content and chemical composition, other properties such as sensitivity to initiation and detonation velocity also may be improved.

Abstract: An embedment system with controlled shrinkage for use with a composite-modified double-base propellant composition which is comprised of an embedment granule portion in percent by weight of nitrocellulose of about 23.0, nitroglycerine of about 8.8-13.8, triacetin of about 1.2, bisspiro orthocarbonate from about 2.5-5.0, resorcinol of about 1.5, 2-nitrodiphenylamine of about 1.0, ammonium perchlorate (10 micrometers) of about 48.5 and aluminum powder (20 micrometers) of about 10.0 and an embedment resin portion in percent by weight of bisphenol A-epichlorohydrin of about 50.0, epoxidized dimer acid of about 50.0, and a curative which is comprised of equal parts mixture of methylenedianiline, m-phenylenediamine, and i-propyl-m-phenylenediamine with an added accelerator of 2,4-dinitrophenol. This embedment system employs a specific bisspiro orthocarbonate, 3,9-bis(5'-norbornene-2'-yl)-1,5,7,11-tetraoxaspiro[5.

Abstract: A primer mix which contains from 26 to 66 weight percent titanium and from 74 to 44 weight percent potassium perchlorate having a density of from 68 to 81 percent of crystal density such that the mix is stable at high temperature up to 525.degree. F. for more than 100 hours without degradation and requires a relatively high amount of impact energy greater than 4 ft.-lbs. in order to ignite it. Alternatively, the primer mix contains from 40 to 74 weight percent zirconium and from 60 to 26 weight percent potassium perchlorate having the above density. The primer mix is used in a percussion primer for initiating combustion or in a percussion initiator for detonating a high-order explosive, as used for example within wellbores in the oil and gas industry.

Abstract: Pyrotechnic devices are described which are intended to emit an illuminating flux starting from multiple, exact, movable sources, particularly suitable for displays of artificial fireworks. The illuminating pyrotechnic devices consist of a shell which contains a block of a pyrotechnic composition consisting of at least a polymerized binder, an oxidizer and a combustible metal. For the purpose of achieving the bursting of the composition into a multitude of incandescent fragments when the device is ignited, the pyrotechnic composition consists of a binder of the phenoplastic type and an oxidizer, the granulometry of which is lower than 150 micrometers and the block, the smallest dimension of which is greater than 15 mm, has undergone a rapid cooling which gives rise to internal strains and fracture points within the composition.

Abstract: An improved embedment system is disclosed which is comprised of an embedm granule portion in percent by weight of nitrocellulose of about 23.0, nitroglycerine of about 15.0, resorcinol of about 1.5, 2-nitrodiphenylamine of about 1.0, ammonium perchlorate (10 micrometers) of about 45.5, and aluminum powder (20 micrometers) of about 14.0 and an embedment resin portion in percent by weight of bisphenol A-epichlorohydrin of about 44, epoxidized dimer acid of about 20, and a curative which is the condensation product of 2 moles of 1,2-bis(maleimido)ethane and one mole of triaminotriazine of about 36.0. This embedment system has superior characteristics of a high peel strength and greater resistance to penetration by or absorption of carboranylmethyl propionate or casting solvent absorption.

Abstract: A curable binder for use in forming a castable propellant of the hydroxy-terminated polybutadiene type which uses a combination of two bonding agents, an aziridine polyester and an amine polyester. The amount of aziridine polyester is reduced by a factor of 3 to 4 compared to known systems. Improved propellant properties, including elongation at maximum load and at rupture, while maintaining comparable tensile strength and initial moduli, are obtained. A diisocyanate curing agent, an antioxidant such as di-tert-butylhydroquinone or phenyl-beta-naphthyl amine and combinations of antioxidants, and isodecyl pelargonate as a plasticizer, may be included.

Abstract: Disclosed is a method for increasing the burning rate of solid propellants hich contain metal staples and/or metal flakes, etc., through the use of an electrical field effect created by the application of direct-current to a propellant grain placed between direct-current electrodes. This method also provides a means of correcting for anisotropy of burning rate in propellants which contain metal staples, metal flakes, etc., where non-random orientation may occur at the motor wall and mandrel surface.

Abstract: This invention concerns itself with the addition of certain copper salts and chelates to solid propellant formulations as burning rate modifiers. The additives increase the burning rate of the propellant while simultaneously decreasing its pressure exponent.

Abstract: A process is disclosed by which thermoplastic elastomers may be utilized to repare melt-formable composite rocket propellants. The thermoplastic elastomer is dissolved in a volatile organic solvent, the other propellant ingredients are mixed in, and the volatile organic solvent is evaporated. The dried propellant is melt-formed to final shape by molding or extruding above the melting point of the elastomer. An example of a usable thermoplastic elastomer is a block copolymer comprised of about 5 to about 20 weight percent styrene and of about 80 to 95 weight percent diene. The formed grain can be reclaimed by melting or dissolution in an organic solvent for reuse of the propellant ingredients.

Abstract: A solid propellant formulation and method of preparation which has enhanced urning rate characteristics and improved mechanical properties. The formulation comprises a binder, a fuel and an inorganic oxidizer consisting of ammonium perchlorate whiskers which are oriented along the direction of shear.

Abstract: This patent describes a novel desensitized explosive wherein a normally sitive solid explosive material is coated with an effective desensitizing amount of a phlegmatizing agent which contains functional groups reactive with one or more ingredients conventionally used in forming a thermally stable, crosslinked solid composite explosive. The present invention also includes thermally stable, crosslinked solid composite explosive in which said desensitized explosives are an integral part. Still further this invention includes the method of coating the as-received explosive material with said phlegmatizing agent, preferably in a drying vessel at elevated temperatures.

Abstract: A potting compound, comprising a low viscosity and low temperature curing licone resin, potassium perchlorate, magnesium and boron, for encapsulating electronic equipment and assemblies and which can be used for destroying the electronic components in emergency situations.

Abstract: A solid rocket propellant composition having a relatively high low pressure deflagration limit (Pdl) and thereby capable of being extinguished with only a relatively small drop in combustion chamber pressure. The composition comprises a major amount of finely divided ammonium perchlorate and a minor amount of fluoroalkyl acrylate or methacrylate polymer as a binder, the weight ratio being from about 4.5:1 to about 6:1.The fluidity of the composition prior to curing can be improved by incorporating a small amount of an acrylate or methacrylate having an oxygen-containing functional group, e.g., hydroxyalkyl, epoxyalkyl and glycerol acrylates and methacrylates.

Abstract: The reaction products formed from tri-functional aziridinylphosphine oxides r their derivatives reacted with monofunctional carboxylic acids, the tri-aziridinyl derivatives of triazine, the tri-aziridinyl derivatives of benzenetriacyl, the aziridine compound N-phenethylaziridine, and selected alkyl diaziridine compounds are representive of the aziridine compounds which are utilized in isocyanate curable composite propellant compositions to extend usable pot life required for mixing and processing of the specified compositions. The compositions are comprised of a binder of hydroxy terminated liquid polymer systems, (e.g. hydroxy terminated polybutadiene and the like) selected plasticizers, optional metal fuel, and the inorganic oxidizer, ammonium perchlorate, that is substantially of very fine particle size (less than 20 microns).

Abstract: Fuel-rich propellant compositions, for use in air-augmented rocket propulsion, containing a high-energy fuel component in the form of finely-divided boron, wherein the boron is present in large excess of the amount oxidizable during combustion of the propellant. A major portion of the boron is ejected, largely as free boron particles, together with the combustion products of the propellant and is burned downstream of the propellant by ram air injected into an afterburner combustion zone. The propellant additionally comprises an organic fuel binder comprising an organic polymer, and an inorganic oxidizer salt, preferably ammonium perchlorate, in an amount at least sufficient to maintain stable combustion of the propellant at desired combustion chamber pressures. The propellant compositions may additionally contain small amounts of Mg, Al, or Zr metal as ballistic or afterburner combustion modifiers.

Abstract: Trioctylphosphine oxide and tributylphosphine oxide are representative of e phosphine oxide compounds which are utilized in isocyanate curable composite propellant compositions to extend usable pot life required for mixing and processing of the specified compositions. The compositions are comprised of a binder of hydroxy terminated liquid polymer systems, (e.g. hydroxy terminated polybutadiene and the like) optional selected plasticizers, optional metal fuel, and the inorganic oxidizer, ammonium perchlorate, that is substantially of very fine particle size (less than 20 microns).

Abstract: Sub-micron particle size ammonium perchlorate particles are made by mixing a solution of ammonium perchlorate in a volatile liquid with a second less volatile liquid which is miscible with the first liquid and is a non-solvent for ammonium perchlorate. The resulting mixture is heated to vaporize the volatile liquid and form a suspension of fine ammonium perchlorate particles in the second liquid. A particle coating agent soluble in the second liquid is used to limit particle growth. The particles are coated with the coating agent and may be recovered from the suspension by vaporization of the second liquid to form a powder, or by partial evaporization of the second liquid to form a concentrated slurry or paste in which the ammonium perchlorate is the disperse phase. The ultra-fine particles formed are suitable for use in propellant formulations.

Abstract: The compound 2-ferrocenyltetrahydrofuran in solid propellant compositions a ballistic modifier. This ballistic modifier increases the burning rate and improves the performance of the particular solid propellant composition in which it is incorporated. The propellant compositions contain in addition to said ballistic modifier, a binder, an oxidizer and a metal fuel.

Abstract: A solid propellant composition employing 2,2-bis(t-butyldicyclopentadienyon)propane (TBD) as the burn rate enhancer in a weight percent from about 2 to about 6 weight percent yields higher threshold values for ignition by impact and improved friction and spark testing values to thereby render the solid propellant composition less hazardous to personnel during handling as compared to similar solid propellant compositions containing Catocene, (2,2-bis(ethyldicylopentadienyliron)propane). The TBD solid propellant composition also comprises from about 9 to about 10 weight percent of hydroxyterminated polybutadiene binder system including an isocyanate curative added in amount of up to 1.0 weight percent and optional modifiers in small amounts with adjustment of the weight percent of other ingredients. Other propellant ingredients comprise a trimodal mix of 200, 1.7, and 0.