Abstract: A rocket motor nozzle has a nozzle core that defines a nozzle passage through which combustion products travel during flight. The erosive forces created by the combustion products are longitudinally distributed over the nozzle core so that the nozzle's smallest area remains substantially constant in spite of the erosion. An inner surface of the nozzle core defines the nozzle passage. The inner surface includes an entry region which defines a nozzle entry, an exit region which defines an exit, and an elongate erosion region which defines an erosion passage between the entry and exit. The erosion region length is greater than the average smallest passage diameter, thereby allowing the location of the erosion focus along the erosion region to vary over time as a result of erosion of the erosion region. The nozzle core is formed of a fibrous composite material which is selected according to the type of propellant used and which includes fibers oriented transverse to the erosion passage to resist erosion.

Abstract: Solid rocket motor propellant formulations are provided which are capable of burning at at least two selected burn rates. The burn rate is controlled by controlling the pressure at which the propellant burns. For example, it is possible to mechanically modify the container, such as a rocket motor casing, in which the propellant is held in order to modify the pressure under which the propellant burns. Alternatively, the propellant may be configured or molded such that the pressure changes at a chosen time due to the process of burning the propellant. The propellant is capable of burning at a relatively constant burn rate at a chosen pressure. Once the pressure changes which chosen limits, the burn rate of the propellant is rapidly modified to another relatively constant burn rate. The solid rocket motor propellant is formulated with the addition of from about 0.5% to about 4.0% TiO.sub.2. The specific operating pressures and burn rates can be selected by modifying the amount of TiO.sub.

Abstract: A pressure vessel for holding a pressurized fluid such as compressed natural gas ("CNG") includes two end cells and zero or more interior cells. The cell geometry ensures that the cells meet one another at tangential circular surfaces, thereby reducing the tendency of adjacent cells to peel apart. A web secured about the cells includes two sheets that are tangent to the cells. Unused volumes between the cells and the web contain wedges of foam or rubber. A valve provides fluid communication between the interior of the pressure vessel and a pressurized fluid line. The filled weight of one pressure vessel does not exceed the filled weight of a conventional gasoline tank that occupies substantially the same space as the pressure vessel. The pressure vessel may be configured with exterior recesses for engaging conventional gasoline tank straps.

Abstract: Energetic materials are continuously processed in a twin-screw extruder to provide safe, low-cost, high quality manufacturing of pyrotechnic compositions, gun propellants, and high explosives. The energetic materials are processed by first lacquering the binder and other soluble ingredients in a solvent. The lacquer solution is introduced into a twin-screw extruder. At least one solid reactive material ingredient, such as metal and/or oxidizer particles, is also introduced into the twin-screw extruder. The solid reactive material ingredient and the lacquer solution are mixed within the twin-screw extruder. After mixing, sufficient solvent is removed by heating or by vacuum to permit bulk granulation of the energetic material. Moist energetic material is then granulated using a remote continuous rotary granulator. The energetic material is dried to produce free-flowing granules which may be used as feedstock for further processing.

Abstract: The present invention is directed to a novel pressure vessel and process for manufacturing the pressure vessel. In one embodiment, the invention includes a case for a rocket motor which includes a cylindrical, metal shell which has been configured with a plurality of slots positioned in axially extending rows. A fiber reinforced plastic layer is attached to the metal shell. Each slot has a length (L) and is separated by adjacent slots in the same row by an axial distance (A) with adjacent rows of slots separated by a circumferential distance (C) and configured such that L+A.gtoreq.6C and L.gtoreq.4A. The method of the invention comprises using a CO.sub.2 laser to cut a keyhole in the shell and then cutting axially outwardly from the keyhole to form the slot, resulting in slots having a width equal to the cutting width of the laser. The beam is then defocused and used to heat a portion of the metal shell surrounding the ends of each slot to produce a tempered zone.

Abstract: An infrared decoy flare having enhanced infrared intensity is disclosed. The flare includes a case in which an infrared illuminant composition is disposed. The bore diameter and length of the case are advantageously selected to be compatible with preexisting chaff dispensers and their cartridges located on aircraft. The illuminant composition, the nozzle throat area, the geometry of the illuminant composition, and the volume of the combustion chamber are selected such that combustion of the illuminant composition results in an unstable combustion condition during the first second of combustion, thereby increasing the peak intensity of the radiation emitted by the propellant. Preferably, the flare is configured such that the unstable combustion occurs during the first 0.2 to 0.5 seconds of combustion of the illuminant composition.

Abstract: A PBAN-based solid rocket motor propellant which includes more than 85% or more solids is provided. Propellants of this nature are possible using the combination of diepoxide curing agents and PBAN as a binder. The curing agents include diepoxides having 4 to about 10 carbon atoms. It has been observed that when a diepoxide curing agent is substituted for conventional curing agents, viscosities are significantly reduced, thus enabling the addition of higher percentages of solids in the propellant formulation. Total solids loading of over 85% are achievable while maintaining end-of-mix viscosities within acceptable ranges.

Abstract: Conductive carbon fibrils are incorporated into energetic compositions to reduce electrostatic discharge susceptibility. The carbon fibrils are grown catalytically from carbon precursors and are substantially free of pyrolytically deposited thermal carbon. The fibrils generally have a length in the range from about 1.mu. to about 10.mu. and a diameter in the range from about 3.5 nanometers to about 75 nanometers. Length to diameter aspect ratios are greater than 5, and typically in the range from about 100:1 to about 1000:1. An effective amount of fibrils is included in the energetic compositions to decrease the resistivity to a level below or on the order of about 10.sup.10 ohm-cm. In most cases, fibril concentration will be in the range from about 0.005 to about 0.1 weight percent.

Abstract: Composite pressure vessels having improved fiber strength translation of the unidirectional, axial, impregnated strand are obtained by a process in which chemorheologically viscosity tailored matrix resin formulations containing surface-active agents or compounds acting as surface-active agents are employed. The use of chemorheologically viscosity tailored matrix resin formulations containing surface-active agents reduces the strength variation of pressure vessels produced from prepregs of the disclosed matrix resin formulations.

Abstract: A scanning system (10) for inspecting a surface (16) including a light source (30) which generates a beam of light (32) that is reflected, scattered or causes fluorescence at the surface to be inspected. An optical interface (14) receives the beam of light and directs it along a predetermined path extending to and from the surface. An acousto-optic tunable filter (34) tuned to pass light having a wavelength corresponding to a known optical property of a predetermined material is positioned within the path of light. A detector (42) is positioned to receive light emanating from the surface and is configured to monitor the intensity of light at each predetermined wavelength being monitored and generate a corrsponding signal. The system is preferably attached to a scan board (90) thereby enabling the system to be used in scanning a surface. The system also includes a signal processor (22) which processes the signal generated by the detector. The resulting data is displayed by an output device (26).

Abstract: An energetic binder system useful for making TPE-LOVA propellants and energetic composites comprises at least one thermoplastic elastomer, at least one plasticizer, and nitrocellulose.

Abstract: A method for securing a boss to a thermoplastic liner of a pressure vessel are disclosed. A preferred method of forming the vessel includes inserting a thermoplastic projection of the liner into a mounting aperture located in the boss. The projection, which is rigidly attached to the liner, mechanically prevents rotation of the boss about a pressure chamber orifice relative to the liner. The method further includes melting and compressing the thermoplastic projection to conform it to a locking chamber in the mounting aperture. A composite case is then constructed over the thermoplastic projection, the liner, and the boss, using the liner as a mandrel. The thermoplastic liner and projection are integrally formed by blow-molding thermoplastic material into a die without any substantial use of injection-molding. A vessel constructed according to the method is also disclosed.

Abstract: A device for producing an electrical output within a larger apparatus which generates the electrical output by use of energy already available within the apparatus. The device is particularly adaptable for use within an apparatus which incorporates an explosive charge which detonates during the operation of the apparatus. The device employs a piezoelectric cell which is positioned within the apparatus at a location such that when a force or shock wave is generated within the apparatus, that force is at least partially applied to the piezoelectric cell. Thus, an electrical voltage is generated by the piezoelectric cell. The device also includes a wire or other device for transporting the electrical energy to an appropriate location for use. The device may be placed within a flare of the type propelled by a rocket motor and also having an explosive charge for separating the rocket motor from the remainder of the flare.

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: A process forms decoy flare pellets which satisfy predetermined burn requirements without milling additional grooves into the pellet flare material after that material is consolidated. The process includes providing sufficient surface area to the flare material during consolidation to eliminate the need for milling. Consolidated flare pellets are then coated with an ignition composition and installed in a decoy flare housing.

Abstract: The use of 4,10-dinitro-2,6,8,12-tetraoxa-4,10-diazatetrocyclo[5.5.0.0.sup.5,9 0.sup.3,11 ]-dodecane as the major explosive ingredient in compositions useful in high performance, low sensitivity explosive applications is disclosed.

Abstract: A process of degrading nitramines by mixing the nitramine with an aqueous dispersion of metal powders and by heating the mixture is disclosed. HMX and RDX are typical nitramines which are degraded according to the present invention. Metal powders which have been successfully used include aluminum and zinc. The weight ratio of nitramine to metal powder is less than about 17:1. The aqueous mixture of nitramine and metal powder is preferably heated to a temperature greater than about 50.degree. C. and up to the boiling point of the mixture. Best results have been obtained when an aqueous base is used in connection with the metal powder. Aqueous ammonia and dilute hydroxide salt solutions are currently preferred aqueous base solutions.

Abstract: Smoke-producing compositions are disclosed that combine the low toxicity of an organic acid smoke and the high obscuration effect of a red phosphorus (RP) smoke. Phosphoric acid produced by RP is neutralized by an acid scavenger added to at least one of the RP or organic acid smoke formulations. To prevent chemical reaction between ingredients of the two smoke-producing formulations, they are separated in the apparatus of the present invention such that only the resulting smokes mix. Very small amount of a RP smoke formulation increases the obscuration index of organic acid smokes comparable to conventional hygroscopic chloride (HC) smokes.

Abstract: A surface preparation process has been developed for aluminum and aluminum 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 aluminum substrates to processing variables such as humidity, temperature and hence the processing timelines. The process involves treating an aluminum surface with a solution of an alkali metal metasilicate, and subsequently treating the surface with a solution of an organofunctional silane. Employing this two step process, bonding to the aluminum substrate is improved.

Abstract: A composition is provided which has at least one salt of 5-nitraminotetrazole and an at least one oxidizer selected from among inorganic nitrates, inorganic nitrites, metal oxides, metal peroxides, organic peroxides, inorganic perchlorates, inorganic chlorates, metal hydroxides, and mixtures thereof. The compositions are useful in the gas generant field.