Abstract: In one embodiment, thermite matches are provided. For instance, thermite matches as described herein may be constructed as a multi-staged formulation comprising an outer ignition tip, an optional inner transition tip, and a bulk fuel thermite stage. The outer ignition tip may comprise an ignition compound that can be struck/scraped against an abrasive counter-chemical surface (e.g., red phosphorous) to initiate the reaction. The outer ignition tip can reach a first burn temperature that can further ignite the inner transition tip stage, which can in turn burn at a temperature that reaches the ignition temperature of the bulk fuel thermite. The high burn temperature of the thermite match may then be used to ignite other materials, such as hard-to-ignite materials, such as a thermite rod for cutting or welding. Other embodiments provide for thermite match handles and a two-piece ignition thermite matches.

Abstract: In one embodiment, a portable thermite fire starter kit is provided. For instance, one or more small pieces or solid blocks of thermite may be contained within a portable kit container along with one or more ignition items. The ignition items may comprise thermite matches. In one embodiment, the ignition items are kept separate from the pieces of thermite. In one embodiment, one or both of the thermite pieces and/or thermite matches are constructed as multiple layers of progressively ignitable materials and/or compounds. In particular, the layers may start at a first layer and that can reach a first burn temperature that is at least a subsequent adjacent layer ignition temperature, where each subsequent intermediate layer leading to the thermite progressively increases in ignition temperature to not more than a previously adjacent layer burn temperature and also increases in burn temperature to at least a subsequent adjacent layer ignition temperature.

Abstract: Exothermic welding molds, weld-metal containing cartridges for such molds, and methods of use are provided. The mold, cartridges, and methods can provide interaction between the cartridge's disk member with the mold, which allows the housing member to be withdrawn from the mold while leaving the disk member and weld-metal in place. The interaction can be a rotational restraint alone, a vertical restraint alone, or combinations thereof. Alternately, the interaction can be an outward pressure on the housing member and/or disk member, a shear force on the housing member and/or disk member, or combinations thereof. The outward pressure on the housing member and/or disk member can alternately be provided without interaction between the disk member and the mold, but rather by the simple application of an internal pressure to the cartridge. The internal pressure can be applied by squeezing the walls of the cartridge and/or by depressing a pusher member.

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

Abstract: Non-lethal payloads may be customized for particular uses and desired visual and audible incapacitation based upon the selection of igniter/activators and illuminants used with the non-lethal payloads. Non-lethal payloads employing high flame temperature igniter/activators and illuminants of powder metals, powdered metals combined with oxidizers, and powdered metals combined with heat-activated chromophores may produce improved “flashes” and “bangs” for non-lethal payloads used with diversionary or other devices. Such devices and methods of producing illuminance and noise are also disclosed.

Abstract: A thermite torch formulation that includes a metal fuel in the form of a magnalium alloy and an oxidizer in the form of MoO3. When the thermite formulation is reacted, a torch may direct at least one reaction product onto a certain region of an object to deliver a large amount of energy to that region of the object.

Abstract: A thermite torch formulation that consists essentially of a metal fuel, a first oxidizer CuO, a second oxidizer MoO3, and a binder material. When the thermite formulation is reacted, a torch may direct at least one reaction product onto a certain region of an object to deliver a large amount of energy to that region of the object.

Abstract: This invention relates to granules comprising a homogenous mixture of metal flakes and/or metal powder and metal oxide powder, and a binder. The invention also relates to a process for producing such granules. The process includes the step of forming a mixture of metal flakes and/or metal powder and metal oxide powder, forming the mixture into a homogenous blend, adding the blend, together with a binder, to a granulator to form granules, and drying the granules. Granules so formed containing aluminium, aluminium oxide and iron oxide find particular use as sensitisers and energisers in explosives compositions.

Abstract: A thermite torch formulation that includes a metal fuel in the form of a magnalium alloy and an oxidizer in the form of MoO3. When the thermite formulation is reacted, a torch may direct at least one reaction product onto a certain region of an object to deliver a large amount of energy to that region of the object.

Abstract: A thermite formulation for use in thermite torch applications made up of from about 3 percent by weight to about 35 percent by weight Mg/Al alloy, from about 30 percent by weight to about 70 percent by weight CuO, and from about 15 percent by weight to about 35 percent by weight MoO3. Additionally, the formulation may also include a binder material.

Abstract: A single increment initiator charge for use in an inflatable restraint system and a method of preparing the single increment initiator charge are provided. The single increment initiator charge includes a homogeneous blend of zirconium, an oxidizer such as potassium perchlorate, and a combustion enhancer such as titanium hydride in an amount effective to result in the single increment initiator charge being effective to ignite an associated pyrotechnic charge. The single increment initiator charge may be formed by preparing a homogeneous blend such as by dry-blending the constituents or by mixing the constituents with a solvent such as an alcohol to form a slurry, loading the homogeneous blend into a charge holder and compressing the homogeneous blend.

Abstract: A low density slurry bridge mix for use in an inflatable restraint system is provided. The low density slurry bridge mix includes zirconium metal, a thermal conductivity enhancer such as aluminum metal, potassium perchlorate oxidant, and a binder material and has a dry density of about 45 to about 65 percent of theoretical density. The low density slurry bridge mix may be used in an initiator including an unground header attached to a raised bridgewire wherein the low density slurry bridge mix surrounds and adheres to the bridgewire.

Abstract: Ammonium nitrate is phase-stabilized by a synergistic phase stabilization additive combination of at least cupric oxide and potassium nitrate. Specifically, phase-stabilized ammonium nitrate contains between about 94.0 and about 96.0 wt. % ammonium nitrate and between about 4 and 6 wt. % of a synergistic phase stabilization additive combination of at least cupric oxide and potassium nitrate, wherein the cupric oxide is present in a relative amount of no more than about 2.0 wt. %. In some cases, additional stability is imparted by the inclusion of zinc oxide such as in a relative amount of no more than about 1.5 wt. %.

Abstract: A thermite composition for pyrotechnics having high heat transfer charactistics comprising a strongly reducible metal oxide, a thermally decomposable heat transfer agent consisting of Cu2O, and a strong reducing agent. It is desirable that the stoichiometerics and mechanics of the thermite reaction is such that there is a substantial excess of oxygen. Also, other ingredients may be added to the composition such as gas generating compounds, binders, diluents and supplemental oxidizing agents.

Abstract: The invention provides a new and improved process and exothermic reaction mixture for producing molten weld metal. The molten weld metal is used in joining one metallic piece with at least one other metallic piece. The process and exothermic reaction mixture have distinct advantages over the prior art. These advantages include a higher filler metal yield, an increased tensile strength, and a higher quality corrosion resistant weld. These advantages are accomplished by a process wherein a reactant mixture is provided which has a reducing agent, a metallic compound, and at least two filler metals that at least in part do not chemically react with the metallic compound, one of which is aluminum. The metallic compound subsequently forms, with the reducing agent, having a high heat of formation which provides an exothermic reaction with sufficient heat to melt the filler metals.

Abstract: Polyethers containing pendant azide groups are cured without a catalyst by yclo-addition with diacetylenes to form triazole cross-linked, energetic binders having improved mechanical properties and stability. The polyethers typically have three hydroxy-terminated chains each of about 5000 to about 50,000 daltons. Ideally, only one azide group per chain reacts by cyclo-addition since the diacetylene is added in a proportion of about one molecule to each two polyether chains. Repeating units of glycidal azide, azidomethylmethyloxetane, bis-azidomethyloxetane/nitratomethylmethyloxetane, and bis-azidomethyloxetane/azidomethylmethyloxetane are believed effective as polyethers when used with the diethynlbenzenes 1,4-bis(ethynl)benzene, 1,4-bis(ethynlcarbonyl)benzene, and 1,3-bis(cyanoethynl)benzene. The polyethers may be further cross-liked at the hydroxyl terminations by urethane bonds.

Abstract: A lead-free percussion primer composition and a percussion cup containing e composition. The lead-free percussion primer composition is comprised of a mixture of about 45 wt % aluminum powder having an outer coating of aluminum oxide and molybdenum trioxide powder or a mixture of about 50 wt % aluminum powder having an outer coating of aluminum oxide and polytetrafluoroethylene powder. The aluminum powder, molybdenum trioxide powder and polytetrafluoroethylene powder has a particle size of 0.1 .mu.m or less, more preferably a particle size of from about 200-500 angstroms.

Abstract: An improved heat generating thermite composition suitable for use in an inflator of a motor vehicle airbag restraint system comprises a hard consolidated pellet, grain or wafer shaped formulation of a powdered metal fuel, a powdered metal oxide oxidizer, a binder and a supplemental oxidizing agent.

Abstract: Autoigniting compositions containing a hydrazine salt of 3-nitro-1,2,4-triazole-5-one for the gas generator of a vehicle occupant restraint system result in rapid autoignition at temperatures from approximately 150.degree. C. (302.degree. F.) to 220.degree. C. (428.degree. F.) thereby allowing the gas generator to operate at lower temperatures to facilitate use of an aluminum canister. The autoignition compositions of the present invention are relatively insensitive to shock or impact, are safe to manufacture and handle, and are advantageously classified as Class B materials.

Abstract: The present invention relates to metal filaments for use as fuel additives for rocket propellants, explosives, and other pyrotechnic devices. Preferred filaments are those such as zirconium, niobium and titanium (and alloys thereof) which have very high heat of combustion.

Abstract: Emulsifiers are disclosed which comprise the reaction product of component (I) with component (II). Component (I) comprises the reaction product of certain carboxylic acids or anhydrides, or ester or amide derivatives thereof, with ammonia, at least one amine, at least one alkali and/or at least one alkaline-earth metal. Component (II) comprises certain phosphorus-containing acids; or metal salts of said phosphorus-containing acids, the metal being selected from the group consisting of magnesium, calcium, strontium, chromium, manganese, iron, molybdenum, cobalt, nickel, copper, silver, zinc, cadmium, aluminum, tin, lead, and mixtures of two or more thereof. These emulsifiers are useful in water-in-oil explosive emulsions.

Abstract: A blasting agent is disclosed for use in a borehole having a pressure resistant closure. The blasting agent is used in combination with a primary initiating system comprised of a detonator and an initiator for the detonator. The blasting agent is preferably a semi-fluid explosive material having a predetermined sensitivity. The sensitivity is related to the borehole diameter and the initiating system's strength, wherein the blasting agent upon initiation is transformed into explosive products by means of reaction front which consumes substantially all the blasting agent as the reaction front passes through the blasting agent. The reaction front has an average velocity of propagation of between 200 meters/second and 1,000 meters/second for at least 30% of the total length of blasting agent located in the borehole. Another aspect of the invention is a method of blasting wherein the average velocity of propagation of the explosive front in the blasting agent is in a range of between 200 m/sec and 1,000 m/sec.

Abstract: A pyrotechnic composition containing from 55 to 65 percent by weight Fe.s2 O.sub.3 powder, 15 to 25 percent by weight aluminum powder, 5 to 15 percent by weight Ba(NO.sub.3).sub.2, 2 to 3 percent by weight MoS.sub.2 and 5 to 10 percent by weight Viton A (a copolymer of vinylidene fluoride and hexafluoropropylene) is disclosed as being useful in the destruction of metal oxide-semiconductor chips.

Abstract: A gas generating grain has a water-based particulate booster coating thereon. The coating comprises an alkali metal azide, a water-soluble inorganic oxidizer in approximately a stoichiometric proportion of oxidizer to azide, and a nucleating amount of a small particle size metal oxide, preferably selected from the group consisting of iron oxide, nickel oxide and aluminum oxide. The coating is applied to said grain from a water slurry and dried, and when dried has an average particle size of less than about 50 microns.

Abstract: Pyrotechnic delay compositions with delays in the seconds range are based on a pyrotechnic delay mixture of powdered metallic tungsten, barium chromate an potassium perchlorate, and additionally contain either barium hexafluorosilicate or calcium fluoride pyrogenic silica. The additives cause these compositions to burn completely even under severe environmental conditions, such as very fast rotation, vibration, impact, shock, and, at the same time, extremely low below-freezing temperatures. The effect of the barium hexafluorosilicate is still further improved if the delay compositions additionally contain pyrogenic silica.

Abstract: A method of safely detoxifying mustard gases comprises reacting the gases a first reaction with incandescent pyrophoric metallic powder compounded in specific formulation. A second reaction enhances the neutralization of the toxicity of the mustard gases by thermal pyrolysis or deflagration. To accomplish the basic reaction which results in formation of thiacyclopentane, aluminum powder which is a preferred incandescent, pyrophoric metallic powder, is compounded in a basic formulation of aluminum powder, a binder, a curing agent, oxidizing agent, and burn rate catalyst. Examples of detoxification formulation which accomplishes the first reaction as well as a second reaction which enhances the neutralization of the toxicity of the mustard gases or toxic chemical agents by thermal pyrolysis or deflagration are shown under Table II and Table III.

Abstract: A high acceleration high performance solid rocket motor grain such as for a ballistic defense missile or rocket assisted projectile comprises a propellant material which includes a highly plasticized binder so that the grain has a solids ratio equal to at least about 95 percent. In order that the grain with such a solids ratio may have adequate strength and withstand high acceleration forces, a reticulated structure is embedded therein. A method of constructing a rocket motor having such a grain is also disclosed.

Abstract: The disclosure relates to a method of producing pyrotechnical charges by mixing and granulating the included components in water, a considerable advantage from the point of view of safety. The method according to the invention also makes it possible to vary the percentage concentration of the included components so that the obtained pyrotechnical charges can either be used as delay charges or as ignition charges. Since, moreover, an acrylate binder is included, they will obtain superior mechanical strength properties.

Abstract: In a process for the production of a `water-in-fuel` or `melt-in-fuel` emulsion explosive a density-reducing agent is introduced and dispersed in the emulsion at an elevated temperature whereat the emulsion is essentially liquid, the explosive is cartridged and then subsequently cooled by means of a refrigerated fluid so that the continuous phase solidifies and stabilizes the dispersion of the density-reducing agent in the explosive. Preferably, when the density-reducing agent comprises gas bubbles the explosive is subjected to an elevated pressure before it is cartridged in order to ensure that the sensitivity of the explosive will not be impaired by disturbance of gas bubbles by any pressure drop which might occur during cartridging.

Abstract: The invention concerns a method and a smoke-producing pyrotechnical ammunition to shield the visible and infrared radiance in a wave length included between 0.4 and 14 .mu.m emitted by a target. First we produce instantly a first hot aerosol with a fast pyrotechnical composition, which masks the target through diffusion in the visible spectrum and with its emitting potential in the infrared zone. Then, we produce a second aerosol which contains hot carbon particles of which the size is included between 1 and 14 .mu.m with a slow pyrotechnical composition for shielding mainly through diffraction the thermal image emitted by the target. The fast composition includes zinc and zinc oxide, potassium perchlorate, hexachlorobenzene or hexachloroethane powder and a binding agent. The slow composition includes a compound which generates carbon particles of 1 to 14 .mu.

Abstract: Structure for generating nitrogen gas for inflating an air bag vehicle occupant restraint comprises a grain made of an azide based material which generates gas upon combustion. The grain is made of a gas generating material which includes 61-68% by weight of sodium azide, 0-5% by weight of sodium nitrate, 0-5% by weight of bentonite, 23-28% by weight of iron oxide, 1-2% by weight of fumed silica, and from about 2 to about 6% by weight of graphite fibers having a diameter of 3-15 microns and an average length of 40 to 125 thousandths of an inch.

Abstract: A dry, water-activated, exothermic chemical formulation useful as a deicing agent on surfaces, which includes magnesium metal and magnesium oxide, and at least one chloride salt to depress the freezing point of water and prevent the buildup of snow and ice on surfaces.

Abstract: A primer composition using manganese dioxide as the predominant oxidizer is disclosed. The manganese dioxide oxidizer is combined with a fuel source and non-metallic initiating explosive material. Various diazo, triazole, or tetrazole compounds may be used as non-metallic initiating explosives, although diazodinitrophenol is preferred. The combustion by-products of the invention do not include toxic oxides of lead, barium, or mercury. The invention therefore provides distinct safety and environmental advantages.

Abstract: A new arrangement of matter is developed which can be formulated to be a high explosive, a propellant or a gas generator. The new arrangement of matter in its explosive embodiment is known as a microknit composite explosive (MCX) in which an essentially anhydrous mixture of perchlorate based oxidizer salts, surfactants and organic fuels is prepared while the oxidizer is molten, and a microcrystalline property is created which imparts a hard, machinable characteristic to the arrangement of matter.

Abstract: A new arrangement of matter is developed which can be formulated to be a high explosive, a propellant or a gas generator. The new arrangement of matter in its explosive embodiment is known as a eutectic microknit explosive (EMCX) in which an essentially anhydrous eutectic mixture of ammonium nitrate, soluble explosive, and other oxidizing salts is mixed with surfactants and organic fuels while the eutectic mixture is molten, and a microcrystalline property is created which imparts a hard, machinable characteristic to the arrangement of matter.

Abstract: A new arrangement of matter is developed which can be formulated to be a high explosive, a propellant or a gas generator. The new arrangement of matter in its explosive embodiment is known as a microknit composite explosive (MCX) in which an essentially anhydrous mixture of inorganic salts, surfactants and organic fuels is prepared while the oxidizer is molten, and a microcrystalline property is created which imparts a hard, machinable characteristic to the arrangement of matter.

Abstract: The tracer unit, which is particularly adaptable for ammunition used in hand guns and submachine guns, consists of a base charge including about 70 to about 90 weight % strontium peroxide, about 5 to about 15 weight % calcium resinate and about 5 to about 10 weight % magnesium and an igniter charge covering the base charge and including about 40 to about 60 weight % calcium resinate, about 20 to about 30 weight % strontium nitrate and about 20 to about 30 weight % magnesium. A small cavity in the rear end of a projectile is partially filled with the base charge which is tamped into the cavity by the application of a low pressure, such as by hand tamping with a metal plunger or the like. The igniter charge is added to the projectile cavity on top of the base charge and, after drying, the exposed surface of the igniter charge is covered with a compatible moisture proofing material, such as shellac.

Abstract: Explosives that are sensitized blends of inorganic nitrate, e.g., AN, particles, such as AN or ANFO prills, and an aqueous slurry comprising a thickened aqueous solution of an inorganic oxidizing salt, preferably AN, are rendered storage-stable by keeping the slurry's water content low enough, and its viscosity high enough, that the slurry is water-retentive. Water immobilization in the slurry, a requirement for storage stability, is achieved despite the slurry's flowable consistency at the time of blending. A blend containing about 25% slurry or less, is essentially in the form of a granular mass of free-flowing, high-density, slurry-bearing prills, and the slurry is sensitizable by the prills alone. As the slurry content exceeds about 25%, the blend takes on the characteristics of a thick slurry, requiring a supplemental sensitizer in the slurry per se.

Abstract: A priming composition with an elevated thermal stability, which is sensit to percussion, is disclosed. The priming composition comprises a tetrazolic ring containing primary explosive and a sensitivity additive. The sensitivity additive comprises an oxidizing agent and a reducing agent. 40 to 95 weight percent of the priming composition is the primary explosive, 2.5 to 40 weight percent of the priming composition is the oxidizing agent and 2.5 to 40 weight percent of the priming composition is the reducing agent. The priming composition is applied to heads of percussion fuses.

Abstract: A method of minimizing deep hole pressure effects on ammonium nitrate-containing blasting agents while optimizing booster sensitivity, detonation rate and detonation energy of such agents, by replacing density control component(s) with a sensitizer formulation comprising particulate aluminum and particulate smokeless powder; and a corresponding detonatable high density emulsion blasting agent utilizing such sensitizing formulation.

Abstract: A water-in-oil emulsion explosive composition containing hollow microspheres obtained by firing volcanic ash and having a bulk density of 0.05-0.1 and an average particle size of 10-100 .mu.m has improved explosion performance and safety over water-in-oil emulsion explosive composition containing conventional hollow microspheres.

Abstract: A gas-retaining agent having a particle size of 177-3,000 .mu.m is effective for improving the safety of water-in-oil emulsion explosive compositions against methane and coal dust and for improving the sympathetic detonability of the explosive compositions without deteriorating their strength.

Abstract: A gas-retaining agent consisting of bubble assemblies, each bubble assembly being one particle consisting of a large number of bubbles agglomerated into the particle, is effective for improving the safety of water-in-oil emulsion explosive compositions against methane and coal dust, for improving the sympathetic detonability of the explosive compositions and for lowering their detonation velocity without deteriorating their strength.

Abstract: An incendiary mixture which is constituted of metals with at least one oxygen-supplying metal oxide and an organic binder, and/or a nitrate, chlorate, perchlorate or peroxide selected from the group of elements consisting of sodium, potassium, lithium, barium, strontium, as well as compounds of ammonium.

Abstract: This invention concerns a dynamite type explosive composition which comprises at least one liquid explosive nitric ester and an emulsion composition comprising an oxygen-releasing salt phase, an organic phase and an emulsifier. The invention provides dynamite type compositions in which the amount of liquid explosive nitric ester can be significantly reduced without adversely affecting the performance and physical properties of the composition.

Abstract: This invention concerns a water-in-oil emulsion explosive composition which comprises a discontinuous aqueous phase containing one or more oxygen-releasing salts, a continuous water-immiscible organic phase comprising sump oil, and an emulsifying agent. The explosive compositions show improved sensitivity over conventional compositions made using paraffin oil as the organic phase.

Abstract: A pyrotechnic spotting charge for training projectiles contains 30-50% zinc owder, 10-30% aluminum powder, 10-30% potassium nitrate or sodium nitrate, and 10-30% potassium perchlorate. The composition (a) is fast reacting and produces a large volume of white smoke visible at a great distance before the projectile buries itself in the ground and (b) is of low brisance and does not cause fragmentation of the projectile.

Abstract: A stacked load of gas-forming pyrotechnic fuel pellets comprising metal, metal oxide and PTFE in varying amounts for use in apparatus for severing conduits in high pressure environments.