Abstract: A solid propellant dual pulse rocket motor has a pressure vessel containing two pulse grains separated by a barrier insulator. An igniter assembly disposed at a fore end of the pressure vessel selectively ignites a first pulse grain from a central channel within the grain. The igniter assembly also ignites a second pulse grain by ejecting hot combustion gases onto the fore end of the grain. Using such an ignition arrangement, a dual pulse rocket motor may be constructed using standard off-the-shelf ignition components.

Abstract: Complex generating compositions and methods for their use are provided. Metal complexes are used as gas generating compositions. These complexes are comprised of a cationic metal template, sufficient oxidizing anion to balance the charge of the complex, and a neutral ligand containing hydrogen and nitrogen. Hyradzine 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. Such complexes are adaptable for use in gas generating devices such as automobile air bags.

Abstract: A continuous process of manufacturing black powder and black powder substitute using a twin screw extruder is disclosed. Guar gum mixed with the composition at a concentration in the range from 0.05% to 0.5%, by weight, dramatically reduced the friction in the dies and permitted extrusion of the powder at much lower water levels. Different size dies used in combination with face cutting of the extruded strands produce various sized granules. The process can be operated remotely and automatically. The process reduces the number of buildings, equipment and personnel required to manufacture black powder or black powder substitute. The process produces more uniform and reproducible particle sizes.

Abstract: A covert, i.e., no visible light emitted, multispectral day/night target marker is disclosed. The marker emits a signature detectable in the electromagnetic spectrum including visible, near infrared, middle and longwave infrared, and radar regions. The marker is particularly useful for marking of target areas so that they can be easily detected from the ground or the air. The visible spectrum is marked by a white or colored pyrotechnic smoke generant. The near infrared region is marked by near infrared emitting photodiodes encased in a hardened polymeric molding compound. These diodes are only visible through night vision devices (image intensifiers). The middle through the far infrared regions are marked by the heat generated from the combustion of the pyrotechnic smoke generant. The smoke generant is housed in a canister having a highly emissive surface. The radar region is marked using radar chaff. The target marker is configured for use with conventional mortar or rocket delivered flare systems.

Abstract: A surface preparation process has been developed for titanium and titanium alloy substrates that greatly improves the resulting bond. The process improves bond strength, fracture toughness, durability and failure mode of adhesive bonds. The process also decreases the sensitivity of titanium substrates to processing variables such as humidity, temperature and hence the processing timelines. The process involves treating a titanium or titanium alloy surface with a soluble silicate solution, such as an alkali metal metasilicate, and subsequently treating the surface with a solution of an organofunctional silane. Employing this two step process, bonding to the titanium substrate is improved.

Abstract: An aerodynamically stable, kinematic flare having an enhanced plume signature is disclosed. The flare includes a housing with a flare illuminant disposed within the housing. A primary nozzle is configured in the aft wall of the housing. Four secondary nozzles are configured in the aft end of the side wall of the housing and are positioned aft of the center of gravity of the flare. At least two of the secondary nozzles comprise off-center nozzles having a longitudinal axis which does not extend through the longitudinal axis of the flare. A shroud is attached to the housing and deploys to an extended position upon combustion of the illuminant. The shroud is configured with holes which correspond in size and position to each of the secondary nozzles when the shroud is in its extended position. The primary and secondary nozzles are sized and positioned to spin stabilize the flare during combustion of the illuminant.

Abstract: A nonsolvent process of synthesizing bis(2,2-dinitropropyl)acetal (BDNPA) is disclosed. In the process, 2,2-dinitropropanol (DNPOH) is reacted at low temperature with an acetaldehyde source in the presence of an acid catalyst, such as a Lewis acid catalyst or protic acid catalyst. To inhibit by product formation, the reaction temperature is maintained from about -30.degree. C. to 30.degree. C. Upon completion of the reaction, the reaction solution is quenched with water and washed with an aqueous hydroxide solution. The hydroxide concentration should be sufficient to neutralize any acid formed during the quenching step and to solubilize unreacted 2,2-dinitropropanol as well as other aqueous soluble byproducts in the reaction solution. The BDNPA product is extracted with methyl tert-butyl ether (MTBE) or equivalent solvent. The organic solvent is evaporated to yield usable BDNPA product. The resulting yield is at least 50% based on the starting quantity of 2,2-dinitropropanol.

Abstract: The addition polymerization resin systems phthalonitrile, diethynyldiphenyl methane, phenolic triazine, and polyphosphazene are disclosed as the matrix constituent in fiber-reinforced ablative nozzle components. Various types of fibers such as carbon fibers, preferably rayon and polyacrylonitrile (PAN) based, graphite fibers, glass fibers, ceramic fibers, and silica fibers may be used in the nozzle composite materials. Fillers, such as carbon black, ground silica, ground petroleum coke, and microballoons, may also be included in the ablative nozzle components. The fiber-reinforced ablative nozzle components include from about 20% to about 40% resin, by weight, from about 45% to about 60% fiber, by weight, and when present, from about 3% to about 15% filler, by weight.

Abstract: A low shear modulus vulcanizate for construction of flexible bearings, particularly for rocket motors, consisting essentially of a mixture of two natural or synthetic rubber copolymers, the first having about 92% cis-1,4-polyisoprene and about 8% trans-1,4-polyisoprene moieties and the second having about 98% by weight cis-1,4-polyisoprene and about 2% by weight trans-1,4-polyisoprene moieties. The composition is lightly filled and contains a low proportion of sulfur, so the vulcanizate has the required low shear modulus, low rate of thermal crystallization at low temperatures, and an acceptably high shear strength.

Abstract: Convert infrared tracer compositions are provided. The compositions are formed using peroxide such as strontium peroxide and barium peroxide. Added to these materials is a burn rate catalyst such as boron, iron oxide, cupric oxide, manganese dioxide, carbon, silicon, graphite fibrils, amorphous silica, copper oxide, potassium dodecaborate, the dipotassium salt of bitetrazole amine, and the potassium salt of dilituric acid. The composition also includes alkali metal compounds in order to enhance the infrared emissions. The compositions are bound together using a binder such that the composition results in a granular material having a mean particle size in the range of from about 500.mu. to about 800.mu..

Abstract: An apparatus for cutting a path of propellant grain away from a solid rocket motor, The apparatus includes a telescoping arm connected to a rotatable body.

Abstract: A propellant system is disclosed which includes a propellant applied to at least one surface of a substrate which is in the form of a strip. The propellant strip is adhesively attached to itself in a configuration which conceals propellant within the configuration and which allows the attached strip to peel away from itself under applied forces thereby resulting in smooth and continuous exposure of propellant for burning. The system is directed to use with ejectable projectiles which are slidably disposed within a canister or casing. The propellant system is interconnected between the projectile and the cannister which houses the projectile. The propellant is urged to peel, and thus expose propellant for burning, as the projectile is ejected from the canister. Alternatively, the propellant is telescoped and covered with a sleeve which peels away as the projectile is ejected.

Abstract: A membrane seal assembly separating forward and aft combustion chambers of a rocket motor. The assembly covers the aft surface of a bulkhead having apertures therein to preclude flow communication between the combustion chambers during combustion of propellant within the aft combustion chamber. The assembly includes a membrane which has a plurality of sectors which open along hinge lines away from the bulkhead to allow flow communication between the combustion chambers when a higher pressure is present in the forward combustion chamber than in the aft combustion chamber, i.e., during subsequent combustion of the propellant in the forward combustion chamber.

Abstract: A decoy flare is disclosed which includes illuminant disposed within a housing. A shroud is slidably attached to the housing for deployment from a retracted position to an extended position. A plug is attached to the aft end of the shroud and is configured with a radially beveled, nozzle-contacting surface. The plug is positioned and configured to sealingly engage the nozzle when the shroud is in the retracted position and to disengage the nozzle upon deployment of the shroud to the extended position. The plug is configured with a plume-contacting surface positioned at an angle to the path of the plume when the shroud is in the extended position for enhancing the cross-sectional area of the plume of the flare.

Abstract: A solid propellant dual pulse rocket motor has a pressure vessel containing two pulse grains separated by a barrier insulator. An igniter assembly disposed at a fore end of the pressure vessel selectively ignites a first pulse grain from a central channel within the grain. The igniter assembly also ignites a second pulse grain by ejecting hot combustion gases onto the fore end of the grain. Using such an ignition arrangement, a dual pulse rocket motor may be constructed using standard off-the-shelf ignition components.

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 cationic metal template, sufficient oxidizing anion to balance the charge of the complex, and a neutral ligand containing hydrogen and nitrogen. 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. Such complexes are adaptable for use in gas generating devices such as automobile air bags.

Abstract: Chemorheologically viscosity tailored matrix resin formulations for use in forming prepregs and composite articles are disclosed. These formulations have a specified viscosity profile obtained from a curable matrix resin and an effective amount of a reactive resin curing agent reactive at room temperature and a latent resin curing agent substantially nonreactive at room temperature. The latent resin curing agent is activated upon heating or radiation. The matrix resin formulation is adapted upon formulation to have a viscosity sufficiently low enough to enable the matrix resin to impregnate fibers or broadgoods at room temperature without the necessity for the application of heat or solvent and which, upon standing at room temperature after impregnation into the fibers or broadgoods to form a prepreg composition, rises in viscosity.

Abstract: A family of high performance, clean, space motor/gas generator solid propellants based on polyglycidyl nitrate elastomer binder, ammonium nitrate oxidizer and small amounts of aluminum and/or boron and which do not require the presence of plasticizers. A high performance, space motor/gas generator solid propellant based on a polyglycidyl nitrate elastomer binder and ammonium nitrate oxidizer optimizes performance at low solids levels.

Abstract: Infrared illuminant compositions are disclosed which produce significant quantities of infrared radiation when burned but which produce very little visible light. The infrared illuminant compositions provide specific illumination in the spectral range visible with night vision devices. The disclosed infrared illuminant compositions include ammonium nitrate as the main oxidizer, an infrared generator such as cesium nitrate, rubidium nitrate, or mixtures thereof, and a fuel. By eliminating potassium and its direct and indirect visible light contributions, from the illuminant compositions, improved concealment indexes are obtained. Other additives, including conventional binders and burn rate modifiers may be used as to tailor the performance and physical characteristics of the infrared illuminant composition.

Abstract: High solids pressable explosive compositions containing a liquid energetic polymer and a high performance explosive oxidizer are disclosed. The pressable explosive compositions contain a solids content between 91 and 99 weight percent, with an energetic polymer content less than 9 weight percent. The energetic polymer has a weight average molecular weight greater than 10,000, determined using a polystyrene standard, sufficient to use the polymer precipitation technique in preparing the pressable explosive compositions. Chain-extended PGN (polyglycidyl nitrate) is a preferred energetic polymer. The pressable explosives disclosed herein produce extremely high detonation pressure, high detonation velocity, and excellent metal accelerating capability.