Abstract: A crucible assembly is suited for use melting aluminum cans at a campfire or similar fire. The crucible assembly may include a handle design that facilitates safe and easy handling of the crucible after it has been heated and contains melted aluminum. The crucible assembly may also include a portion having a convex surface that maintains contact with the ground during rotation of the crucible, thereby providing support and stability to the crucible as melted aluminum is poured therefrom.

Abstract: Methods and apparatus for forming platforms and flow control features in underground wells is described, using modified thermite reactions to form a ceramic plug in place. The reactive package is engineered to expand laterally, filling the well, and may be used to form a ceramic bridge plug, porous ceramic screen sections, or mitigate lost circulation of drilling fluids. These objectives are achieved through the design of the reactive package and through use of carefully chosen reaction additives that control the molten product rheology, solidification temperature, and pore generations and sustainment.

Abstract: A reduced toxicity pyrotechnic strobe composition and method includes creating a mixture of strontium nitrate, magnalium, sulfur, and no more than 10 parts by weight of a nitrocellulose binder. The strontium nitrate may comprise 27 percent of the mixture. The magnalium may comprise a 50:50 blend of magnesium and aluminum. The magnalium may comprise 18 percent of the mixture. The sulfur may comprise 55 percent of the mixture. The mixture may include a pulse rate of approximately one pulse per minute. The method may further include modifying the pulse rate of the mixture. The method may further include using a reduced particle size of the magnalium. The method may further include substituting no more than 12.5% of the strontium nitrate with potassium nitrate.

Abstract: The present invention relates to a water-based non-sensitized matrix or explosive suspension which itself has a rheological behavior such that it allows mechanically loading upward boreholes. This suspension behaves like a viscous liquid when it is forced to flow due to the action of a loading pump, and, however, has the characteristics of a soft solid when it is on standby once inside the borehole. The composition essentially consists of an aqueous solution of oxidizing salts and optionally water-soluble fuels and/or sensitizers, and one or more water-soluble polymers conferring the desired rheological characteristics. Particles of oxidizing salts with a grain size such that they enhance the rheological behavior characteristic of the suspension are dispersed in this aqueous solution.

Abstract: A tool set for preparing a joint, inserting an implant or removing an implant from a joint in an open or less invasive procedure generally comprises a set of nested tools, pin guides, jigs, and/or immobilization elements. The nested tool set comprises at least one pin and at least one cannulated tool. The cannula can comprise tangs that project from the distal end of the cannula. The tangs can be offset such that drilling removes different amounts of bone relative to drilling through a centered drill guide. The cannulated tool kit can comprise at least one tool guide/cannula, drill bits/reamer, syringe, and/or inserter. At least one cannula is positioned over and around the pin position into the joint. The channel of the cannula guides the other tools into the joint.

Abstract: A conductive element of a cable or a wire is formed of a high shear deformation processed aluminum alloy. The aluminum-zirconium alloy exhibits high electrical conductivity and high tensile strength. Methods of forming cables and wires are also further disclosed including the formation of all aluminum alloy cables having high ampacity.

Abstract: A reduced toxicity pyrotechnic strobe composition and method includes creating a mixture of strontium nitrate, magnalium, sulfur, and no more than 10 parts by weight of a nitrocellulose binder. The strontium nitrate may comprise 27 percent of the mixture. The magnalium may comprise a 50:50 blend of magnesium and aluminum. The magnalium may comprise 18 percent of the mixture. The sulfur may comprise 55 percent of the mixture. The mixture may include a pulse rate of approximately one pulse per minute. The method may further include modifying the pulse rate of the mixture. The method may further include using a reduced particle size of the magnalium. The method may further include substituting no more than 12.5% of the strontium nitrate with potassium nitrate.

Abstract: The use of exploding targets has become a popular practice aid in the military, law enforcement and consumer levels. The inventor has conceived and reduced to practice, in a preferred embodiment of the invention, a safe explosive target formulation that is initiated by low-velocity impact. This formulation represents a binary explosive in that the fuel and oxidizer are packaged separately until directly prior to use. Safe, explosive targets for high velocity applications are common. A formulation for low velocity projectile applications which employs an aluminum/magnesium alloy fuel and a potassium perchlorate/ammonium nitrate oxidizer is described.

Abstract: O-Chlorobenzylidene malononitrile (CS) based self-combustible pyrotechnic compositions containing polycarbonate (PC) as a binder and 9,10-anthraquinone as a smoke component capable of producing tear gas smoke upon ignition. The pyrotechnic composition comprises an oxidizer and fuel. The formulation further comprises a stabilizer.

Abstract: Systems and methods for a heated gas cylinder assembly are disclosed. The heated gas cylinder assembly may comprise a cylinder shell and a heat exchanger disposed within the cylinder shell. The heat exchanger and the cylinder shell may define an interior chamber configured to hold a gas mixture. The heat exchanger may comprise an inner bore configured to receive a pyrotechnic composition. In response to igniting the pyrotechnic composition, the heat exchanger may provide thermal conduction to the gas mixture. The gas mixture may be simultaneously heated and released, or the gas mixture may be preheated before release.

Abstract: A hydrogen-propelled projectile for using with a firearm eliminates cleaning the firearm and a method of making the projectile eliminates storing explosive propellant. The projectile has a cylindrical brass body closed at top and sealed at bottom with a primer and a brass seal. When the projectile is used with the firearm, the primer ignites hydrogen in the presence of oxygen, producing water vapor and energy that propels projectile toward a target. To make the projectile a salt water solution is electrolyzed to produce hydrogen and oxygen. A mixture of hydrogen and oxygen is then fed to a loader. The loader fills up the projectile, attached at a gas outlet, with gas by exerting pressure on gas using a load piston and channeling gas to the projectile. Finally, the loader seals the projectile with the primer by pressing a primer ram and affixing the primer at bottom of the projectile.

Abstract: The invention provides mechanically activated metal fuels for energetic material applications. An exemplary embodiment involves mechanically treating micrometer-sized particles of at least one metal with particles of at least one fluorocarbon to form composite particles containing the at least one metal and the at least one fluorocarbon.

Abstract: The invention provides mechanically activated metal fuels for energetic material applications. An exemplary embodiment involves mechanically treating micrometer-sized particles of at least one metal with particles of at least one fluorocarbon to form composite particles containing the at least one metal and the at least one fluorocarbon.

Abstract: A solid state thermite reaction composition is provided comprising a fuel component, an initiating oxidizer, a primary oxidizer, a fluxing agent and a thermal diluent. According to another aspect, a heating device is provided comprising a heating chamber for receiving and storing a substance to be heated having at least two walls, a reaction chamber affixed to a wall of the heating chamber, a solid state thermite reaction composition located within the reaction chamber and an actuatable trigger mechanism affixed to the reaction chamber such that the trigger mechanism is in contact with the reaction composition. According to another aspect, a solid-state thermite reaction activation mechanism is provided comprising a first compound substantially in contact with a thermite reaction fuel, a second compound and a removable barrier located between the first and second compounds preventing any contact between the first and second compounds.

Abstract: A lead-free pyrotechnic and primary explosive compositions including metal iodates as an oxidizer in nanocomposite energetic compositions including metal powder fuel.

Abstract: Perchlorate-free flare compositions are disclosed which, when burned, produce yellow smoke and flames. Methods of producing the compositions are also disclosed.

Abstract: Disclosed are thermite charges for use in well perforation and downhole fracing. The thermite charges have a core, and optionally a case, where at least one of the core and the case includes thermite material.

Abstract: The present invention is a flare illuminant composition, useful in hand-held signals, which composition is environmentally friendly and economical, containing a commercially available, aromatic, high energy, amine-based organic compound, 5-aminotetrazole, in place of the conventional and toxic KClO4, or, for the known alternative to KClO4, expensive, strontium bis-(1-methyl-5-nitriminotetrazolate)monohydrate.

Abstract: A priming mixture is provided having a primary explosive and an oxidizer system containing bismuth oxide. The priming mixture generally is applicable to any application or device that employs ignition of a propellant or fuel, including, but not limited to, air bag gas generator systems, signaling devices, ejection seats, small or large arms ammunition primers, and the like.

Abstract: A thermite composition includes at least one composite particle having a convoluted lamellar structure having alternating metal oxide layers including a metal oxide and metal layers including a metal capable of reducing the metal oxide. The metal oxide layers and metal layers both have an average thickness of between 10 nm and 1 ?m. Molar proportions of the metal oxide and metal is within 30% of being stoichiometric for a thermite reaction.

Abstract: A large-scale synthetic method that enables the preparation of nanoenergetic composites in kilogram scales which forms superior materials as compared to the ultra-sonicated nanoenergetic composites and at a lower cost for use in explosive, pyrotechnic, agent defeat, ammunition primers, and propellant applications.

Abstract: Perchlorate-free flare compositions are disclosed which, when burned, produce yellow smoke and flames. Methods of producing the compositions are also disclosed.

Abstract: A reactive material that includes at least one of a fuel, an oxidizer, and a class 1.1 explosive and is formulated for use in a reactive material projectile. The reactive material is formulated to provide at least one of an overpressure of greater than approximately 9 pounds per square inch at a radial measurement of 12 inches from a point of impact on a target, a hole greater than approximately 2 square inches at an optimum penetration level in a target, and pressure, damage, and a flame when the reactive material bullet impacts a target. The fuel may be a metal, a fusible metal alloy, an organic fuel, or mixtures thereof. The oxidizer may be an inorganic oxidizer, sulfur, a fluoropolymer, or mixtures thereof. A reactive material projectile having the reactive material disposed therein is also disclosed.

Abstract: Improved electric primer compositions, structures, and methods that are compatible with existing munitions and in particular an exemplary electric primer composition including carbon nanotubes along with energetic primer mixture(s) and an exemplary primer structure including layers of energetic materials wherein a layer exhibiting the most energetic character is positioned proximate to a primer button. Alternative embodiments include both conductive and non-conductive layers.

Abstract: The present disclosure relates to a high-density rocket propellant and associated recoilless launching systems and methods with tungsten powder added providing substantial mass to the propellant for additional impulse, absorption of sound, optimization of back blast and carry weight, and the like. In an exemplary embodiment, the high-density rocket propellant includes tungsten mass percentages of between about 70%-about 80%, equivalent to about 17%-about 26% by volume.

Abstract: An electrically initiated security device includes a first energetic sheet, a second energetic sheet, and a corrugated energetic sheet disposed between the first energetic sheet and the second energetic sheet. A first surface of the corrugated energetic sheet defines at least one channel and a second surface of the corrugated energetic sheet defines at least one channel. The electrically initiated security device further includes a first constituent portion disposed in the at least one channel defined by the first surface and a second constituent portion disposed in the at least one channel defined by the second surface. The first constituent portion and the second constituent portion, when mixed, comprise an energetic material.

Abstract: A primer composition that includes stabilized, encapsulated red phosphorus, at least one oxidizer, at least one secondary explosive composition, at least one light metal, and at least one acid resistant binder. The stabilized, encapsulated red phosphorus may include particles of red phosphorus, a metal oxide coating, and a polymer layer. The metal oxide coating may be a coating of aluminum hydroxide, bismuth hydroxide, cadmium hydroxide, cerium hydroxide, chromium hydroxide, germanium hydroxide, magnesium hydroxide, manganese hydroxide, niobium hydroxide, silicon hydroxide, tin hydroxide, titanium hydroxide, zinc hydroxide, zirconium hydroxide, or mixtures thereof. The polymer layer may be a layer of epoxy resin, melamine resin, phenol formaldehyde resin, polyurethane resin, or mixtures thereof. A percussion cap primer that includes the primer composition, a tertiary explosive composition, and a cup is also disclosed, as are ordnance devices including the primer composition.

Abstract: A missile includes a pyrotechnic charge. The missile is constructed in such a way that the pyrotechnic charge is made to burn deflagratively when the missile is used correctly. The pyrotechnic charge includes a mixture containing at least one metal or a metal alloy as a fuel and at least one metal oxide as an oxidizing agent. The fuel and the oxidizing agent are selected in such a manner that they can react with one another by burning. The mixture is compressed to a density of at least 85% of a theoretical density of the mixture, and the fuel, the oxidizing agent and a quantitative ratio between the fuel and the oxidizing agent are selected in such a manner that a density of the mixture is at least 6 g/cm3.

Abstract: The invention provides methods for making homogeneous metal oxide nanoenergetic composites. A method of the invention forms a metal oxide nanostructure via a sol-gel process with surfactant templating. Metal nanoparticles are introduced into the metal oxide nanostructure via wet impregnation.

Abstract: A non-toxic, non-hydroscopic percussion primer composition and methods of preparing the same, including at least one explosive component that has been traditionally considered a moderately insensitive explosive or secondary explosive, and at least fuel particle component having a particle size of about 1.5 microns to about 12 microns, which allows the use of moderately active metal oxidizers. The sensitivity of the primer composition is created by the interaction between the moderately insensitive explosive and the fuel agent such that traditional primary explosives such as lead styphnate or DDNP are not needed. The primer composition also eliminates the risks and dangers associated with traditional nano-sized fuel particles.

Abstract: A method for forming a metastable intermolecular composite (MIC) includes providing a vacuum level of <10?8 torr base pressure in a deposition chamber. A first layer of a first material of a metal that is reactive with water vapor is deposited, followed by depositing a second layer of a second material of a metal oxide on the first layer. The first and second material are capable of an exothermic chemical reaction to form at least one product, and the first and second layer are in sufficiently close physical proximity so that upon initiation of the exothermic reaction the reaction develops into a self initiating chemical reaction. An interfacial region averaging <1 nm thick is formed between the first layer and second layer from a reaction of the first material with water vapor. In one embodiment, the first material is Al and the second material is CuOx.

Abstract: A composition of matter for an incendiary device includes a thermate component consisting of strontium nitrate Gr A, black iron oxide Gr B, aluminum Gr D Cl 5, aluminum Gr E Cl 6, sulfur Gr E, and polyacrylic rubber; and an ignition component consisting of potassium nitrate, titanium, aluminum, silicon, sulfur, charcoal, and polyacrylic rubber, wherein the thermate component consists of a barium nitrate free thermate formulation, and wherein the ignition component consists of a lead free ignition formulation. A parts by weight composition of the thermate component consists of 20.59% strontium nitrate Gr A, 48.04% black iron oxide Gr B, 17.57% aluminum Gr D Cl 5, 9.88% aluminum Gr E Cl 6, 1.96% sulfur Gr E, and 1.96% polyacrylic rubber, and a parts by weight composition of the ignition component consists of 66% potassium nitrate, 11% titanium, 8% aluminum, 6% silicon, 2% sulfur, 5% charcoal, and 2% polyacrylic rubber.

Abstract: The invention is directed to a solid, porous material, suitable for generating nitrogen gas, said material having a porosity of 20 to 75 vol. %, and a composition comprising, based on the weight of the material of 60 to 90 wt. % of sodium azide, 0.1 to 20 wt. % of an inert chemical coolant based on at least one inorganic salt having a heat capacity of at least 1400 J/K/kg, 0.1 to 20 wt. % of modifying agent selected from metal oxides and metal carbonates, and a binder, selected from the group consisting of at least one alkali metal silicate, preferably waterglass, or a poly-tetrazole, in an amount of between 3 and 15 wt. %.

Abstract: A percussion primer composition that comprises an explosive and a sensitizer, the explosive being a moderately insensitive explosive having an impact sensitivity in the range from about 0.3 kp m to about 0.75 kp m. The moderately insensitive explosive may comprise CL-20, PETN, RDX, HMX, or mixtures thereof. The sensitizer may comprise aluminum, titanium, zirconium, magnesium, melamine, styrene, lithium aluminum hydride, or mixtures thereof. In some instances, the percussion primer composition may comprise the moderately insensitive explosive precipitated onto the sensitizer. The percussion primer composition may contain an oxidizer, which in certain situations comprises a conventional oxidizer or a bismuth compound. The bismuth compound is bismuth trioxide, bismuth subnitrate, bismuth tetroxide, bismuth sulfide, or mixtures thereof. A gun cartridge and other primer-containing ordnance assemblies employing the percussion primer composition are also disclosed.

Abstract: A percussion primer composition including at least one explosive, at least fuel particle having a particle size of about 1500 nm or less, at least one oxidizer, optionally at least one sensitizer, optionally at least one buffer, and to methods of preparing the same.

Abstract: A percussion primer composition including at least one explosive, at least one nano-coated fuel particle having natural surface oxides thereon, at least one oxidizer, optionally at least one sensitizer, optionally at least one buffer, and to methods of preparing the same.

Abstract: Solid composite propellants are provided that include a matrix comprising an energetic oxidizer and a binder. A multi-layered reactive thin film is provided in the matrix. The reactive thin film includes metal and inorganic oxidizer. Methods of making the solid composite propellants are also provided.

Abstract: Silicon-based explosive devices and methods of manufacture are provided. In this regard, a representative method involves: providing a doped silicon substrate; depositing undoped silicon on a first side of the substrate; and infusing an oxidizer into an area bounded at least in part by the undoped silicon; wherein the undoped silicon limits an exothermic reaction of the doped silicon to the bounded area. Another representative method involves: providing a doped silicon substrate; depositing a masking layer of low-pressure chemical vapor deposited (LPCVD) Silicon nitride to the first side of the substrate; patterning the nitride mask and etching the porous silicon, and infusing oxidizer into an area bounded by the LPCVD nitride; wherein the silicon nitride limits an exothermic reaction of the doped silicon to the bounded area.

Abstract: Embodiments of the invention provide munitions that are optimized for both performance and safety. According to various embodiments of the invention, primers are provided having reduced sensitivity by using less sensitive ingredients. The primer formulations according to embodiments of the invention provide primers that are insensitive to stimulants that tend to cause inappropriate ignition of main propelling charges.

Abstract: An energetic material composition includes a reducing material and an oxide of phosphorus. The reducing material includes a reducing metal and, in an optional hydride form, auto disperses products of the reaction by the formation of a gaseous product. The composition can be included in a cavity of a warhead. A method of neutralizing a targeted species and a method of reducing structural integrity of civil engineering structures by reacting the composition are also provided.

Abstract: Combustible structural composites and methods of forming same are disclosed. In an embodiment, a combustible structural composite includes combustible material comprising a fuel metal and a metal oxide. The fuel metal is present in the combustible material at a weight ratio from 1:9 to 1:1 of the fuel metal to the metal oxide. The fuel metal and the metal oxide are capable of exothermically reacting upon application of energy at or above a threshold value to support self-sustaining combustion of the combustible material within the combustible structural composite. Structural-reinforcing fibers are present in the composite at a weight ratio from 1:20 to 10:1 of the structural-reinforcing fibers to the combustible material. Other embodiments and aspects are disclosed.

Abstract: A laminated energetic device is disclosed. The laminated energetic device includes a low-gas generating energetic mixture, a core on which the low-gas generating energetic mixture is located, and a protective film for sealing the low-gas generating energetic mixture between the core and the protective film.

Abstract: A metastable intermolecular composite (MIC) and methods for forming the same includes a first material and a second material having an interfacial region therebetween. The first and second material are capable of an exothermic chemical reaction with one another to form at least one product and are in sufficiently close physical proximity to one another so that upon initiation the exothermic reaction develops into a self initiating reaction. At least one of said first and second materials include a metal that is reactive with water vapor at room temperature. The interfacial region averages <2 nm thick, such as <1 nm thick. In one embodiment, the first material is Al and the second material is CuOx.

Abstract: The invention provides homogeneous mesoporous metal oxide nanoenergetic composites. A composite of the invention has a regular and uniform nanostructure of metal oxide, which is structured by a surfactant. Metal fuel nanoparticles are homogenously distributed through the regular and uniform nanostructure. The invention further provides methods for making homogeneous metal oxide nanoenergetic composites. A method of the invention forms a metal oxide nanostructure via a sol-gel process with surfactant templating. Metal nanoparticles into the metal oxide nanostructure via wet impregnation.

Abstract: Boron-containing, green light emitting pyrotechnic compositions that advantageously do not include barium, perchlorate or chlorinated organic compounds.

Abstract: Improved electric primer compositions, structures, and methods that are compatible with existing munitions and in particular an exemplary electric primer composition including carbon nanotubes along with energetic primer mixture(s) and an exemplary primer structure including layers of energetic materials wherein a layer exhibiting the most energetic character is positioned proximate to a primer button. Alternative embodiments include both conductive and non-conductive layers.

Abstract: Perchlorate-free flare compositions are disclosed which, when burned, produce red smoke and flames. Methods of producing the compositions are also disclosed.

Abstract: An apparatus and process for making thermite compositions. The process includes providing a fuel-based slurry and at least one oxidizer-based slurry, formulating combination of fuel-based slurry and oxidizer-based slurry in a solvent to a desired energetic dose depending on nanocomposites' use, circulating the fuel-based slurry/oxidizer-based slurry combination in a mixing device operating semi-continuously during mixing and dispensing cycles forming a homogeneous mixed slurry, agitating ultrasonically or by high shear rate mixers the mixed slurry, and drying of the mixed slurry forming compact structures.

Abstract: The present invention relates to the field of propellant devices and more particularly to the propellant devices used in weapon systems and munitions. The invention has the two advantages of minimizing the risk associated with accidental attack to which propellant devices may be exposed thanks to the filling of the central channel commonly provided along the core of the cylindrical explosive charge and of greatly increasing the effectiveness of these propellant charges by the use of explosive materials having a very high burn rate.

Abstract: An electrically initiated security device includes a first energetic sheet, a second energetic sheet, and a corrugated energetic sheet disposed between the first energetic sheet and the second energetic sheet. A first surface of the corrugated energetic sheet defines at least one channel and a second surface of the corrugated energetic sheet defines at least one channel. The electrically initiated security device further includes a first constituent portion disposed in the at least one channel defined by the first surface and a second constituent portion disposed in the at least one channel defined by the second surface. The first constituent portion and the second constituent portion, when mixed, comprise an energetic material.