Abstract: The invention relates to a new class of alkoxy silane compounds of the following general formula: ##STR1## wherein R is aliphatic or aromatic having from 1 to about 15 carbon atoms and R'comprises a hydrolyzable alkoxy functionality. These compounds are particularly useful as adhesion promoters when used with adhesives such as, for example, phenylethynyl terminated polyimide or polysulfide adhesives. The invention also relates to a method of synthesizing the alkoxy silane compounds defined above.

Abstract: A robust polyurethane liner is disclosed for solid propellant rocket motors which is insensitive to large variations in stoichiometry, exhibits increased cohesive strength and, when used in combination with a unique two coat (wet coat) liner process described below, modifies the ballistic properties of the adjacent interfacial propellant layer. The liner compositions include a polymeric binder having a plurality of reactive hydroxyl functional groups and a curing agent having a plurality of reactive isocyanate functional groups. The quantity of binder and curing agent is selected such that the NCO/OH ratio is in the range from 1.5 to 4.5. Diisocyanate curing agents are particularly useful. A bonding agent, such as a polyfunctional aziridine compound, is typically present in the liner composition in an amount ranging from about 3% to about 5%, by weight. An oligomer catalyst is included in the liner composition in an amount ranging from about 15% to about 50%, by weight. Diammonium phosphate ((NH.sub.4).sub.

Abstract: Liquid nitromalonate polyesters and methods for their preparation are disclosed. Solid propellants are provided which employ as the binder a nitromalonate polyester. These propellants are resistant to plasticizer syneresis and crystallization and provide an increase in the specific impulse of the propellant.

Abstract: A rocket system employing at least one rocket motor closure that includes low and high load capability retainers that, respectively, provide an insensitive munitions system during storage and positive locking of a nozzle assembly at launch. The rocket motor also includes a pressure equalizing system that accommodates changing temperature conditions during storage as well as varying gas pressure inherent in gun-launched rocket systems in a manner that allows for thinner case cylinder design and increased propellant volume.

Abstract: Solid rocket motor propellants which burn at at least one stable burn rate over at least one corresponding pressure range (i.e the burn rate v. pressure curve contains at least one area of low pressure exponent with respect to a normal curve) are described. The propellant compositions comprise a binder, from about 65% to about 90% by weight ammonium perchlorate, the ammonium perchlorate being of at least two distinct particle sizes; from about 0.3% to about 5.0% by weight refractory oxide selected from the group consisting of TiO.sub.2, Al.sub.2 O.sub.3, SiO.sub.2, SnO.sub.2, and ZrO.sub.2 ; and from about 5 to about 25% by weight metal, such as aluminum.

Abstract: A robust polyurethane liner is disclosed for solid propellant rocket motors which is insensitive to large variations in stoichiometry, exhibits increased cohesive strength and, when used in combination with a unique two coat (wet coat) liner process described below, modifies the ballistic properties of the adjacent interfacial propellant layer. The liner compositions include a polymeric binder having a plurality of reactive hydroxyl functional groups and a curing agent having a plurality of reactive isocyanate functional groups. The quantity of binder and curing agent is selected such that the NCO/OH ratio is in the range from 1.5 to 4.5. Diisocyanate curing agents are particularly useful. A bonding agent, such as a polyfunctional aziridine compound, is typically present in the liner composition in an amount ranging from about 3% to about 5%, by weight. An oligomer catalyst is included in the liner composition in an amount ranging from about 15% to about 50%, by weight. Diammonium phosphate ((NH.sub.4).sub.

Abstract: A composition consisting essentially of a polyphosphazene binder having the following repeating units: ##STR1## wherein n is from about 20 to about 50,000, A is selected from --O-- and --NH--, and R.sup.1 and R.sup.2 are independently selected from alkyl having from one to about 20 carbon atoms, aryl having from 6 to about 14 carbon atoms, alkaryl having from 7 to about 30 carbon atoms, any of the preceding moieties substituted with halogen, hydroxyl, alkoxy, aryloxy, or nitro groups, or any of the preceding moieties linked by ether or amine linkages. Combined with an organic fiber filler, this material provides an erosion resistant insulation composition for temporarily protecting the interior of a rocket motor combustion chamber from thermal damage while the rocket is firing.

Abstract: An insensitive composite pressure vessel for containing an energetic compound includes at least two fibers having different temperature resistance characteristics. A dynamic fiber loses a substantial portion of its tensile strength at a transformation temperature which is preferably substantially less than the combustion temperature of the energetic compound, whereas a stable fiber retains substantially all of its tensile strength at temperatures exceeding the transformation temperature. Hence, a pressure vessel formed of dynamic fibers and stable fibers has sufficient burst strength to resist operating pressures under normal conditions. The vessel loses strength and develops additional orifices to vent combustion products from the energetic compound in the event of an external fire, thereby allowing unintentionally ignited rocket motors to burn substantially in place.

Abstract: A decoy flare ignition system is disclosed which includes an ignition initiator disposed at the aft end of the flare housing. An illuminant igniter is positioned in direct contact with the flare illuminant. The illuminant igniter includes at least one illuminant igniter pellet selected such that the firing of the ignition initiator triggers combustion of the illuminant igniter pellet if the safe-and-initiation device has been actuated. The igniter pellet is preferably configured as a circular cylindrical shell and is positioned over the bore of the flare illuminant.

Abstract: A process for manufacturing a high performance gun propellant containing an energetic thermoplastic elastomeric binder and a high-energy oxidizer is disclosed. The process includes preparing or obtaining a molding powder of the high-energy oxidizer particles coated with the energetic thermo-plastic elastomeric binder and extruding the molding powder into the desired gun propellant configuration. The high-energy oxidizer has a concentration in the range from 70% to 85%, by weight, and the energetic thermoplastic elastomeric binder has a concentration in the range from 15% to 30%, by weight. The molding powder has a particle size in the range from 200 .mu. to 2000 .mu.. Typical thermoplastic elastomeric binders include oxetane, oxirane, and nitramine backbone polymers, copolymers, and mixtures thereof. Typical high-energy oxidizers include nitramine oxidizers.

Abstract: A missile diverter for controlling yaw and pitch includes several valve housings secured to an inside surface of a bridge or to a removable cylinder. The valve housings are secured in aligned positions by a layer of integral cured insulation. Gas valves are placed in the housings, and control lines are connected to the valves to allow remote control of the valves during flight. Cups loaded with propellant are secured in place near the valve housings. The valve housings, valves, cured insulation, and propellant cups are then overwrapped and secured within the outer shell of a missile. One method for making the missile diverter includes the step of applying a quantity of uncured insulation to an inside surface of a bridge and to an outside surface of each valve housing. Each valve housing is then positioned within the bridge and the insulation is cured to form an integral layer that holds the valve housings in their aligned positions and forms a hot gas seal.

Abstract: Difunctional, hydroxyl-terminated polymers in which the terminal hydroxyl group is non-primary or hindered are end-capped to provide unhindered, primary, terminal hydroxyl groups which promote an improved cure and improved mechanical properties of the cured elastomer. End-capping chemicals have an hydroxyl-reactive group at one end and a group at the other end which is removable to provide a primary, unhindered hydroxyl group. Short-chain, hydroxyl-terminated polymers are chain-extended with a diisocyanate.

Abstract: Composite propellant formulations are disclosed having a dinitramide salt oxidizer, such as ammonium dinitramide, an energetic binder, such as energetically substituted oxetane and oxirane polymers, a reactive metal, such as aluminum, and other typical propellant ingredients such as curatives and stabilizers. Propellant formulations useful for minimum smoke or reduced smoke applications, preferably include little or no reactive metal. The disclosed propellant formulations are able to combust the reactive metal efficiently, possess high burn rates, and produce little or no HCl exhaust gases.

Abstract: A process for the hydrogenolysis of 2,4,6,8,10,12-hexabenzyl-2,4,6,8,10,12-hexaazatetracyclo?5.5.0.0.sup.5,9.0 .sup.3,11 !dodecane ("HBIW") is disclosed. In the process, a quantity of HBIW, a cosolvent, and a bromine source are placed into a reaction vessel. Acetic anhydride and a palladium hydrogenolysis catalyst are rapidly added to the reaction vessel. The hydrogenolysis catalyst should be substantially free of water. The reaction vessel is purged of an atmosphere capable of reacting with hydrogen, and hydrogen is quickly introduced into the reaction vessel to convert the HBIW to tetraacetyldibenzylhexaazaisowurtzitane ("TADB"). The acetic anhydride is added immediately prior to hydrogen introduction so that the acetic anhydride does not have time to react with the HBIW to form an acetylated derivative prior to commencement of the desired hydrogenation reaction. The process requires very little palladium catalyst, preferably less than 10% wt/wt based on the HBIW substrate.

Abstract: A device for safely attaching sections of a rocket motor is disclosed. The device is constructed such that if the temperature of the rocket motor is elevated to the point where ignition of the propellant within the rocket motor becomes a significant danger, the device allows the sections of the motor to disengage. The device comprises a bimetallic retaining ring which either contracts or expands in diameter upon heating. The retaining ring is positioned in such a manner as to lockingly engage two sections of the rocket motor at normal temperatures. At elevated temperatures, however, the expansion or contraction of the bimetallic retaining ring causes the sections of the motor to unlock from one another, such that if the propellant ignites the sections will disengage and the rocket will be rendered non-propulsive.

Abstract: Gas generating compositions and methods for their use are provided. Metal complexes are used as gas generating compositions. These complexes are comprised of a metal cation template, a neutral ligand containing hydrogen and nitrogen, and sufficient oxidizing anion to balance the charge of the complex. The complexes are formulated such that when the complex combusts, nitrogen gas and water vapor is produced. Specific examples of such complexes include metal nitrite ammine, metal nitrate ammine, and metal perchlorate ammine complexes, as well as hydrazine complexes. A binder and co-oxidizer can be combined with the metal complexes to improve crush strength of the gas generating compositions and to permit efficient combustion of the binder. Such gas generating compositions are adaptable for use in gas generating devices such as automobile air bags.

Abstract: Novel methods for processing gas generant compositions to produce feed stock are disclosed. The methods of the present invention include utilizing a binding agent and other additives in a mixture of ingredients of gas generant compositions in sufficient quantities that the ingredients of the gas generating material will agglomerate to form granules as the ingredients are mixed. Processing methods, including roll coating, continuous mixing, static mixing, freeze drying, solvent extraction, emulsification, azeotropic distillation, spray drying, fluidized bed processing and particle grinding are also disclosed for use in preparing feed stock for final gas generant products. The methods of the present invention are particularly useful in processing gas generating materials having a non-azide based fuel.

Abstract: Gas generating compositions and methods for their use are provided. Metal complexes are used as gas generating compositions. These complexes are comprised of a metal cation template, a neutral ligand containing hydrogen and nitrogen, and sufficient oxidizing anion to balance the charge of the complex. The complexes are formulated such that when the complex combusts, nitrogen gas and water vapor is produced. Specific examples of such complexes include metal nitrite ammine, metal nitrate ammine, and metal perchlorate ammine complexes, as well as hydrazine complexes. A binder and co-oxidizer can be combined with the metal complexes to improve crush strength of the gas generating compositions and to permit efficient combustion of the binder. Such gas generating compositions are adaptable for use in gas generating devices such as automobile air bags.

Abstract: A process of synthesizing HBIW using a mineral acid, such as perchloric acid, as the acid catalyst is disclosed. According to the process, glyoxal, adjusted to a pH from 4 to 7, and benzylamine are reacted in the presence of the mineral acid for sufficient time to form HBIW. The resulting HBIW is then isolated according to conventional separation techniques.

Abstract: A solid composition for generating a nitrogen containing gas is provided. The composition includes an oxidizer and a non-azide fuel selected from a bitetrazoleamine or a derivative or a salt or complex thereof and mixtures thereof. The preferred bitetrazole-amine is bis-(1(2)H-tetrazol-5-yl)-amine, a metal salt, a salt with a nonmetallic cation of a high nitrogen content base or a complex thereof. The salts and complexes are generally metal salts and complexes. The metal can be a transition metal. Metals that have been found to be particularly useful include copper, boron, cobalt, zinc, potassium, sodium, and strontium. The oxidizer is generally a metal oxide or a metal hydroxide. The composition can include certain other components such as secondary oxidizers, burn rate modifiers, slag formers, and binders.