Abstract: The present invention comprises formulations and method for additive manufacturing comprising: a pot-stable photo-curable polymer; one or more fillers; and one or more additives, wherein the formulation cures into a polymer in six hours or less upon exposure to light. In certain examples, the additive manufacturing is a moldless method of additive manufacturing by preparing a formulation comprising: a pot-stable photo-curable polymer, one or more fillers, and one or more additives, and exposing the formulation to light in an amount that substantially cures the polymer in 6 hours or less.

Abstract: The invention relates to a process for forming a pre-defined recess in a cured or cast explosive composition comprising the steps of: i) providing a female mould, ii) providing a male former, and locating said male former proximate to the female mould to create a gap between said male former and female mould, iii) forming an admixture of a curable/castable explosive composition, charging the gap with the admixture of explosive composition, causing the cure or cast of said curable/castable explosive composition, removing the male former to furnish a cured or cast explosive composition with a pre-defined recess.

Abstract: An encapsulated, particulate energetic composition includes one of explosive particles of a known size, oxidizer particles of a known size, and a mixture of explosive particles and oxidizer particles of known sizes, in which particles of one of the explosive particles, the oxidizer particles, and the mixture of the explosive and the oxidizer particles, are encapsulated by a combustible fuel of a known thickness to enhance the energy output. A method of making the encapsulated, particulate energetic composition includes placing one of explosive particles, oxidizer particles, and a mixture of explosive particles and oxidizer particles within a deposition chamber, mixing one of the explosive particles, the oxidizer particles, and the mixture of explosive particles and the oxidizer particles, and depositing, to a known encapsulating thickness, a combustible fuel onto the one of the explosive particles, the oxidizer particles, and the mixture of explosive particles and oxidizer.

Abstract: A method of filling a projectile case with energetic material includes isostatically pressing a column of the powder to create a pre-formed billet (PFB). The single PFB is placed in and then pressed into the projectile case to create the finished warhead. The single PFB effectively fills a projectile case having a large l/d ratio. The single PFB eliminates the problems and poor quality associated with pressing multiple increments in a projectile case.

Abstract: Method for manufacturing a measuring apparatus for determining and/or monitoring at least one process variable. At least one sensor element is inserted into an at least partially pot-shaped mold, and the mold is at least partially filled with a casting material composed at least of a first component and a second component. The mold is filled with the casting material, at least partially, with at least the following steps at least one predeterminable amount of the first component of the casting material is charged into the mold; at least one predeterminable amount of the second component of the casting material is charged into the mold; and the mold is vibrated and/or caused to oscillate with a predeterminable frequency. Furthermore, a method for filling an at least partially pot-shaped mold is disclosed.

Abstract: A sabot petal having an axis parallel to or coinciding with the launch axis. The sabot petal is formed from a plurality of stacked sheets of composite material consisting of a fiber reinforcement and a polymer resin matrix. Each composite sheet is in a plane rotationally offset from the meridional plane which is defined by the launch axis and radial axis of the sabot petal's cylindrical coordinate system.

Abstract: A fender bracket includes a composite structure having a first flange to operatively connect to a fender, a second flange to operatively connect to a vehicle body structure, and a web connecting the first flange and the second flange. At least one actuator is positioned in at least a portion of the web. The at least one actuator is selected from a piezoelectric actuator, an active material actuator, and a pyrotechnic actuator. The at least one actuator is to cause a fracture or buckling of the web in response to an activation signal.

Abstract: A booster explosive (10) is comprised of assembled components comprising a canister body (12, 112) having a fuse tunnel (22) formed integrally therewith and a separate cap well (14, 114) mounted within the canister body (12, 112) which is filled with a solid cast explosive (34). The connector end (14c, 114c, 214c) of cap well (14, 114) is configured to engage cap well mounting fixture (28, 128) disposed within the canister body (12, 112). Cap well mounting fixture (28, 128) has a flexible and resilient crown-shaped locking member (28a, 128a) formed integrally therewith and is otherwise configured to positively retain a detonator (16, 116) within the cap well (14, 114). More than one cap well (214a, 214b, 214a?, 214b?) and more than one fuse tunnel (222a, 222b, 222a?, 222b?) may be provided in the canister body (212, 212?).

Abstract: A proppant comprises a particle and a polyamide imide coating disposed on the particle. A method of forming the proppant comprises the steps of providing the particle, providing the polyamide imide coating, and coating the particle with the polyamide imide coating.

Abstract: To increase the function and safety of a weapon, it is proposed that the molded part, as connecting site particularly between a projectile and a preferably combustible sleeve containing a driving mechanism, be constructed in such a way that, in a predefined region, said molded part has a felt with an energetic material and/or an inert material.

Abstract: A method of making an explosive charge liner comprises introducing powdered material into a basin defined by a die block, where a punch is shaped to interact with the basin, excluding the powdered material from a central portion of the basin, pressing the punch into the powdered material in the basin to form the explosive charge liner, and removing the explosive charge liner from the die block. The explosive charge liner comprises an aperture in an apex area of the explosive charge liner corresponding to the central portion when removed from the die block.

Abstract: An ultra-lightweight, high strength ceramic proppant made from mixture of naturally occurring clays, preferably porcelain clay, kaolin and/or flint-clay, earthenware clay or other naturally occurring clays having an alumina content between about 5.5% and about 35%. The proppant has an apparent specific gravity from about 2.10 to about 2.55 g/cc, and a bulk density of from about 1.30 to about 1.50 g/cc. This ultra-lightweight proppant is useful in hydraulic fracturing of oil and gas wells, and has greater conductivity than sand at pressures up to 8,000 psi as measured by Stim-Lab after 50 hours and 275° F. on Ohio Sandstone, in the presence of deoxygenated aqueous 2% solution of KCI.

Abstract: The present invention provides an improved kinematic countermeasure flare and method of constructing the same wherein the housing has integrated internal features. The flare nose weight is set at the end of a die core prior to molding for integration with the housing. Longitudinal grooves and other recesses in the die core allow for the formation of internal longitudinal ribs which propellant can bond to and a retaining bead for retaining the nose weight in the housing which are integrated with the housing. Propellant is cast into the formed housing. A propellant shaping mandrel is then inserted into the formed housing thereby forcing the propellant into the internal cavity created by the integrally molded longitudinal ribs, the shaping mandrel and the wall of the flare housing such that the propellant is bonded to the interior housing wall and the longitudinal ribs.

Abstract: A method for manufacturing training aid materials for detecting homemade explosives includes spreading an explosive powder on a porous surface, storing the surface in a container that facilitates sublimation of the explosive powder such that the explosive powder redeposits onto the surface and into the pores over a period of time, and removing the surface from the container after the period of time to yield training aid materials. An additional method includes preparing a dilute solution of an explosive reaction mixture, and depositing the dilute solution on a surface prior to formation of an explosive product by the explosive reaction mixture. The surface is stored in a contain that facilitates formation of the explosive product, and removed after a period of time and cleaned to remove unreacted precursors to yield training aid materials.

Abstract: An initiator assembly can include an outer body can have a first end, a second end, and an internal passage between the first and second ends. An initiator canister can be joined to the outer body at the first end and can define a charge chamber that includes a pair of pins extending therefrom. An insulative material can be molded within the passage to form an insulative structural member that joins the canister and pins to the outer body and insulates the pins and a portion of the canister from electrical contact with the outer body. An electrostatic discharge dissipater can be formed from an electrically conductive material and can be molded to the outer body. The dissipater can provide a controlled dissipation path for electrostatic discharge energy carried by the initiator assembly.

Abstract: The Multiple Use Plug Hybrid (for) Nanosats (“MUPHyN”) prototype thruster is being developed to fill a niche application for NanoSat scale spacecraft propulsion. The MUPHyN thruster uses safe-handling and inexpensive nitrous oxide (N20) and acrylonitrile-butadiene-styrene (ABS) as propellants. The MUPHyN thruster can provide an enhanced propulsive capability that will enable multiple NanoSats to be independently repositioned after deployment from the parent launch vehicle. Because the environmentally benign propellants are mixed only within the combustion chamber once the ignition is initiated, the system is inherently safe and can be piggy-backed on a secondary payload with no overall mission risk increase to the primary payload.

Abstract: Igniter base for a pyrotechnic initiator has a glass base together with fused-in contact pins that function as a pole carrier and thus fixes the contact pins in secure correlation to one another. The end side of the glass base and the contact pins form a level plane, so that an ignition bridge resting flush on the glass base can be attached to the poles. The contact pins project beyond the glass base on the opposite side and a part of the glass base and a part of the contact pins projecting beyond the glass base are equipped with a plastic jacketing.

Abstract: A die set for forming explosive charge liners from powdered material is provided. The die set comprises a die block defining a basin and a punch shaped to interact with the basin. The die block and the punch are configured to exclude powdered material from a center axis of the basin.

Abstract: Embodiments of the invention relate to systems and methods for casting hybrid rocket motor fuel grains. In one embodiment, a method for casting a rocket motor fuel grain can be provided. The method can include providing a positive image of a port made from at least one material. The method can further include disposing at least one fuel material around at least a portion of the positive image of the port. Further, the method can include removing the at least one material, wherein a negative image of the port is formed in the at least one fuel material.

Abstract: A malleable solid explosive that is in the form of a solid block consisting, for at least 98% of its weight, of a pulverulent explosive charge and of a liquid chosen from polyol polymers of the group of polyisobutylene polyols, polybutadiene polyols, polyether polyols, polyester polyols and polysiloxane polyols, whose number-average molecular mass is between 500 and 10 000, and mixtures thereof.

Abstract: A cast reactive metal body that can be used as weapon cases is offered. It is cast with aluminum or aluminum alloys with small particles and/or fibers of metals of high density such as molybdenum, tungsten or hafnium. Aluminum alloys are those that can get easily ignited when heated and burn fast afterwards in particulate forms. Metals that react intermetallically with aluminum are excluded. The particles and fibers are of the size between a few microns and a few hundreds of microns in diameter. The length of the fibers is longer than the diameter. The weight percentage of aluminum and/or aluminum alloys range from 10 to 90 percent and the weight percentage of heavy metal particles/fibers ranges from 90 to 10 percent. Other inert materials such as ceramic particles can be added in small amounts.

Abstract: A highly-filled paste, and a method and device of de-aerating and injecting the paste, the paste including: (a) a solid filler; (b) an organic binder, and (c) a residual gas, wherein the paste contains at least 80 volume-% of the solid filler and has a viscosity exceeding 100 kilopascal·seconds, wherein the filler, binder, and residual gas are intimately mixed so as to form a substantially homogeneous paste, and wherein a composition of the solid filler, binder, and residual gas is selected such that the homogeneous paste has: an average density greater than 98.5% of a Theoretical Maximum Density (TMD).

Abstract: With the invention, a method and a device for explosive forming of work pieces, in which at least one work piece is arranged in at least one die and there deformed by means of an explosive to be ignited, is to be improved, in that an ignition mechanism that is technically easy to handle is produced with the shortest possible setup times, which permits the most precise possible ignition of the explosive with time-repeatable accuracy. This task is solved by a method and device, in which at least one work piece is arranged in at least one die and deformed there by means of an explosive being ignited, in which the explosive is ignited by means of at least one energy beam.

Abstract: Provided is a simulant material for simulating hazardous materials, including a quantity of at least one explosive material and at least one inert material. The simulant material is a non-explosive material and is in the form of a homogenous, flexible and non-particulated material. Also provided is a method for manufacturing such a simulant material.

Abstract: The main subjects of the present invention are: a process for obtaining a solid composite propellant (with a polyurethane binder filled with ammonium perchlorate and with aluminum): characteristically, the ammonium perchlorate charge of said propellant is obtained from at least two charges each having a specific monomodal particle size distribution. It is thus sought to reduce the thrust oscillations and the alumina deposits at the back of the engine; a solid composite propellant, the solid propellant charges and the associated rocket engines.

Abstract: A method of manufacturing explosives from a raw explosive material by gelatinizing the raw explosive, characterized in that the raw explosive is subjected to isostatic pressing prior to the gelatinization step.

Abstract: The invention relates to a cast explosive composition comprising a polymer-bonded explosive and a defoaming agent, and to a process for reducing the number and/or total volume of voids in a cast explosive composition comprising the steps of: combining a polymer-bonded explosive and a defoaming agent; and casting the explosive composition. The defoaming agent may be used for reducing the number and/or total volume of voids in a cast explosive composition and the cast explosive composition may be used in an explosive product.

Abstract: A method of manufacturing explosives from a raw explosive material by gelatinizing the raw explosive, characterized in that the raw explosive is subjected to isostatic pressing prior to the gelatinization step.

Abstract: A pourable opaque centerport for solid propellant rocket motors and method for applying the same are disclosed. The pourable centerport inhibitor for solid propellant rocket motors has a curing system that includes a prepolymer and a curing agent. The prepolymer and the curing agent are combined to form a pourable polymeric binder that cures into an amorphous solid. The pourable centerport inhibitor also includes an opaque agent. The pourable centerport inhibitor may also include a plasticizer. The plasticizer, the prepolymer, and the curing agent are preferably the same type that is in the solid propellant with which it will be used in conjunction.

Abstract: The present invention relates to a method and an arrangement for the production of radially perforated, cylindrical propellant tubes (1, 23, 31). The invention is based on the underlying idea that the respective propellant tube (1, 23, 31) must be fixed and centred between its own open ends and thereafter to be perforated in stages in a large number of consecutive perforation operations by means of one or more pins (13) capable of displacement in a pin die (10) relative to the propellant tube towards and at least through the major proportion of the cylindrical wall of the propellant tube. Also included in the invention is the requirement for the displacement, between each perforation operation, of the propellant tube and the pin die (10) used for the preparation operation in such a way relative to one another that the propellant tube, after a complete perforation operation, shall be covered in its entirely by perforations (32, 33, 35, 36), which lie at a predetermined e-dimension distance from one another.

Abstract: The present invention relates to a semi-continuous method for obtaining a composite explosive charge comprising a solid polyurethane matrix loaded with a charge, the charge being in powder form and comprising at least one nitro-organic explosive.

Abstract: The present invention provides pyrotechnic gas generator compounds and a method of obtaining them. Said compounds have a composition which comprises: an oxidizing charge which comprises at least one inorganic perchlorate and which does not comprise a chlorine scavenger; and a crosslinked, oxygen-containing hydrocarbon binder obtained by crosslinking an elastomer in the presence of at least one crosslinking agent and at least one oxygen-containing plasticizer for said elastomer; said elastomer having a molecular weight of more than 200 000 and being preferably selected from polyesters and polyacrylates; said at least one oxygen-containing plasticizer being composed of a plasticizer of which the molecular weight is greater than 350 g/mol and the oxygen balance equal to or greater than ?230 %, of a mixture of such plasticizers with one another or of a mixture of at least one such plasticizer with at least one other oxygen-containing plasticizer. Said compounds can be obtained continuously by extrusion.

Abstract: A solvent-free process is used to make mouldable plastic explosives or mouldable plastic explosive simulant products.

Abstract: A highly-filled paste, and a method and device of de-aerating and injecting the paste, the paste including: (a) a solid filler; (b) an organic binder, and (c) a residual gas, wherein the paste contains at least 80 volume-% of the solid filler and has a viscosity exceeding 100 kilopascal·seconds, wherein the filler, binder, and residual gas are intimately mixed so as to form a substantially homogeneous paste, and wherein a composition of the solid filler, binder, and residual gas is selected such that the homogeneous paste has: an average density greater than 98.5% of a Theoretical Maximum Density (TMD).

Abstract: A method for making high energy compositions, such as propellants, explosives, pyrotechnics or the like, including a solid metal particulate fuel dispersed in a cured binder matrix. The compositions are formed with ingredients including a particulate metal fuel such as boron, binder polymer (such as GAP polyol), binder plasticizer, and a curing agent containing isocyanate. The improved method includes pre-reacting the particulate metal fuel with an amount of isocyanate, which acts as a curative to neutralize residual acid. The particulate metal fuel/isocyanate from the pre-curing step is mixed together with the binder polymer, binder plasticizer, and remaining curing agent to form the solid propellant. The initial neutralization of the metal fuel avoids gassing and improves the mechanical properties of the propellant yield.

Abstract: A method for supplying a pyrotechnic material slurry to a container, includes, taking out a pyrotechnic material slurry, stored inside a storage container, from the bottom portion of the storage container or a vicinity thereof, sealing the exposed surface of the pyrotechnic material slurry with a sealing material, and maintaining the sealed state of the pyrotechnic material slurry in the process of supplying the pyrotechnic material slurry to the container.

Abstract: With the invention, a method and a device for explosive forming of work pieces, in which at least one work piece is arranged in at least one die and there deformed by means of an explosive to be ignited, is to be improved, in that an ignition mechanism that is technically easy to handle is produced with the shortest possible setup times, which permits the most precise possible ignition of the explosive with time-repeatable accuracy. This task is solved by a method and device, in which at least one work piece is arranged in at least one die and deformed there by means of an explosive being ignited, in which the explosive is ignited by means of at least one energy beam.

Abstract: The present invention provides pyrotechnic grains of composition comprising at least one oxidizing charge and at least one reducing charge and no binder. In characteristic manner, said grains are in the form of substantially cylindrical blocks: with a thickness of more than 5 mm; with an equivalent diameter of 10 mm or more; and with porosity in the range 1% to 8%, limits included. Said grains, advantageously based on guanidine nitrate and basic copper nitrate, are suitable for the slow, low-pressure generation of gas over an extended period.

Abstract: The velocity of detonation of an explosive such as detonating cord (18, 22) is controlled by the addition of a diluent to the explosive, e.g., to the core of the detonating cord (18, 22). An explosively inert diluent, or a diluent comprised of an explosive of lower brisance than the principal explosive comprising the core of the detonating cord, will serve to reduce the velocity of detonation. Such reduced velocity of detonation has beneficial effects in certain operations, including cleaving rock (10), wherein it is observed to significantly reduce radial cracks (24) and stickers (26) (long radial cracks) in the vicinity of the boreholes (12) in which the low-velocity detonating cord (18, 22) is functioned to cleave the rock (10). The low-velocity detonating cord also facilitates leaving behind a smoother face in cutting trenches and tunnels through rock.

Abstract: A munition is described including a reactive fragment having an energetic material dispersed in a metallic binder material. A method is also described including forming a energetic material; combining the energetic material with a metallic binder material to form a mixture; and shaping the mixture to form a reactive fragment. The munition may be in the form of a warhead, and the reactive fragment may be contained within a casing of the warhead.

Abstract: High explosives suitable for filling very small volume loading holes in micro-electric initiators for micro-electro-mechanical mechanisms, used as safe and arm devices, are prepared from slurries of crystalline energetic materials including organic liquid and applied using various methods. These methods include swipe loading, pressure loading and syringe loading. The organic liquid serves as a volatile mobile phase in the slurry so as to partially dissolve the energetic material so that, upon evaporation of the mobile phase, the energetic material precipitates and adheres to the loading hole.

Abstract: To increase the function and safety of a weapon, it is proposed that the molded part, as connecting site particularly between a projectile and a preferably combustible sleeve containing a driving mechanism, be constructed in such a way that, in a predefined region, said molded part has a felt with an energetic material and/or an inert material.

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

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

Abstract: Novel reactive composite materials and associated methods for making the same which are pertinent to numerous new or improved applications. The method for making the reactive composite materials utilizes mechanical deformation to manufacture such materials with controlled, predictable characteristics. In the first deformation step, an assembly of reactive layers and/or particles is plastically deformed to reduce its cross sectional area by one-half or more. Portions of the deformed sheets are stacked or bent into a new assembly, and the new assembly is then deformed. The steps of assembly and deformation are repeated a sufficient number of times that the resulting materials are only locally layered but have relatively uniform reaction velocity and heat generating characteristics predictable by stochastic models derived herein.

Abstract: The invention provides an infra-red decoy flare comprising a pyrotechnic composition which comprises an extrudable and energetic binder in an amount in the range of from 4-35 wt %, which binder comprises a nitrocellulose, an oxidator in an amount in the range of from 40-80 wt %, a pyrotechnic fuel in an amount in the range of from 15-35 wt %, and a carbon source in an amount of up to and including 10 wt %, all amounts based on total pyrotechnic composition. The invention further provides a process for preparing said infra-red decoy flare.

Abstract: A shaped, flexible fuel and energetic system is presented. The shaped, flexible fuel comprises at least one polymeric binding material and porous silicon particles dispersed throughout the polymeric binding material. The porous silicon particles are prepared from a metallurgical grade silicon powder. The shaped, flexible fuel preferably includes shapes such as: an article, a film, a wire and a tape. The energetic system comprises the shaped, flexible fuel portion used alone or in combination with at least one oxidizer.

Abstract: There is provided a tubular molded article of a gas generating agent consisting of a non-azide-based composition. Both ends of the molded article are squashed. A gas-generating-agent producing process is to obtain a gas generating agent which is molded into the form of a tube both ends of which are squashed in such a way that the tubular molded article of the gas generating agent being in a wetted state is passed through a gap between a pair of molding gears that are rotatable so that each convex tooth of one of the molding gears can face that of the other molding gear, thereafter the molded article is squashed with the convex teeth at predetermined intervals, thereafter the molded article is cut off at the squashed concave parts in such a way as to be folded, and the resultant cut pieces are dried.

Abstract: A thruster stack assembly and method for manufacturing the same is provided. The thruster stack assembly includes a plurality of grain elements having a common core region (e.g., a channel or passageway), where each grain element comprises a volume of electrically ignitable propellant. The thruster stack assembly further includes electrodes associated with the plurality of grain elements, the electrodes adapted for selectively igniting the plurality of grain elements. In one example, one or more of the grain elements may be ignited and combusted without igniting or damaging adjacent grain elements of the stack. The core region serves to channel combustion gases and exhaust from the thruster stack. Multiple stacks may be assembled together to form three-dimensional thruster arrays.

Abstract: A high energy propellant, comprising an oxetane thermoplastic elastomer energetic binder admixed with a high energy explosive filler. The oxetane thermoplastic elastomer energetic binder preferably comprises from about five percent to about thirty percent by weight and the high energy explosive filler comprises from about seventy percent to about ninety-five percent by weight of the composition. A preferred propellant further includes an explosive plasticizer, preferably in an amount of about four percent to about seven percent of the plasticizer by weight of the propellant. The preferred filler is selected from the group consisting of CL-20, TNAZ, RDX and mixtures thereof. The preferred plasticizer is selected from the group consisting of TNAZ, BTTN, TMETN, TEGDN, BDNPA/F, methyl NENA, ethyl NENA and mixtures thereof.