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ADVANCED EN ERG ETIC MATERIALS
Committee on Advanced Energetic Materials and ManufacturingTechnologies
Board on Manufacturing and Engineering Design
Division on Engineering and Physical Sciences
NATIONAl RESEARCH COUNCIL
OF THE NATIONAl ACADEMIES
THE NATIONAL ACADEMIES PRESS
Washington, D.C.
www.nap.edu
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THE NATIONAL ACADEMIES PRESS 500 Fifth Street, N.W. Washington, DC 20001
NOTICE: The project that is the subject of this report was approved by the Governing Board
of the National Research Council, whose members are drawn from the councils of the
National Academy of Sciences, the National Academy of Engineering, and the Institute of
Medicine. The members of the committee responsible for the report were chosen for their
special competences and with regard for appropriate balance.
This study was supported by Contract No. DSWA01-98-C-0075 between the National
Academy of Sciences and the Defense Special Weapons Agency Since 1998 the Defense
Threat Reduction Agency]. Any opinions, findings, conclusions, or recommendations
expressed in this publication are those of the authors and do not necessarily reflect the
views of the agency that provided support for the project.
International Book Standard Number: 0-309-09160-8 (book)
International Book Standard Number: 0-309-53055-5 (PDF)
Available in limited quantities from:
Board on Manufacturing and Engineering Design
Keck Center of the National Academies
500 Fifth Street, N.W.
Washington, DC 20001
bmaed@nas.edu
http://www. nations l-academ ies.org/bmed
Additional copies of this report are available from the National Academies Press, 500 Fifth
Street, N.W., Lockbox 285, Washington, DC 20055; (800) 624-6242 or (202) 334-3313 (in
the Washington metropolitan area); Internet, http://www.nap.edu
Copyright 2004 by the National Academy of Sciences. All rights reserved.
Printed in the United States of America
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THE NATIONAL ACADEMIES
Advisers lo the Naiion on Science, Engineering, and Medicine
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of
distinguished scholars engaged in scientific and engineering research, dedicated to the
furtherance of science and technology and to their use for the general welfare. Upon the
authority of the charter granted to it by the Congress in 1863, the Academy has a mandate
that requires it to advise the federal government on scientific and technical matters. Dr.
Bruce M. Alberts is president of the National Academy of Sciences.
The National Academy of Engineering was established in 1964, under the charter of the
National Academy of Sciences, as a parallel organization of outstanding engineers. It is
autonomous in its administration and in the selection of its members, sharing with the
National Academy of Sciences the responsibility for advising the federal government. The
National Academy of Engineering also sponsors engineering programs aimed at meeting
national needs, encourages education and research, and recognizes the superior
achievements of engineers. Dr. Wm. A. Wulf is president of the National Academy of
Engineering.
The Institute of Medicine was established in 1970 by the National Academy of Sciences to
secure the services of eminent members of appropriate professions in the examination of
policy matters pertaining to the health of the public. The Institute acts under the
responsibility given to the National Academy of Sciences by its congressional charter to be an
adviser to the federal government and, upon its own initiative, to identify issues of medical
care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of
Medicine.
The National Research Council was organized by the National Academy of Sciences in 1916
to associate the broad community of science and technology with the Academy's purposes of
furthering knowledge and advising the federal government. Functioning in accordance with
general policies determined by the Academy, the Council has become the principal operating
agency of both the National Academy of Sciences and the National Academy of Engineering
in providing services to the government, the public, and the scientific and engineering
communities. The Council is administered jointly by both Academies and the Institute of
Medicine. Dr. Bruce M. Alberts and Dr. Wm. A. Wulf are chair and vice chair, respectively, of
the National Research Council.
www.national academies.org
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COMMITTEE ON ADVANCED ENERGETIC MATERIALS AND MANUFACTURING TECHNOLOGIES
RONALD L. ATKINS, Lawrence Livermore National Laboratory (retiredy, Ridgecrest, California,
Chair
DAVID E. BENDER, Aerojet, Sacramento, California
THOMAS B. BRILL, University of Delaware, Newark
PHILIP M. HOWE, Los Alamos National Laboratory, Los Alamos, New Mexico
MALCOLM F. NICOL, University of Nevada at Las Vegas
JIMMIE C. OXLEY, University of Rhode Island, Kingston
ANITA M. RENLUND, Sandia National Laboratories, Albuquerque, New Mexico
ALBERT A. SCIARRETTA, CNS Technologies, Springfield, Virginia
JEAN'NE M. SHREEVE, University of Idaho, Moscow
ROBERT B. WARDLE, ATK Thiokol Propulsion, Brigham City, Utah
Liaison to the Board on Manufacturing and Engineering Design
ROBERT J. EAGAN, Sandia National Laboratories, Albuquerque, New Mexico
Staff
TONI MARECHAUX, Board Director
CUNG VU, Study Director (until December 2000)
SHARON YEUNG DRESSEN, Study Director (until November 2002)
EMILY ANN MEYER, Research Associate
TERI THOROWGOOD, Research Associate
JUDY ESTER, Senior Project Assistant (until April 2002)
v
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BOARD ON MANUFACTURING AND ENGINEERING DESIGN
PAMELA A. DREW, The Boeing Company, Seattle, Washington, Chair
CAROL ADKINS, Sandia National Laboratories, Albuquerque, New Mexico
THOMAS W. EAGAR, Massachusetts Institute of Technology, Cambridge
ROBERT FONTANA, JR., Hitachi Global Storage Technologies, Alameda, California
PAUL B. GERMERAAD, Intellectual Assets, Inc., Saratoga, California
ROBERT HATHAWAY, OshRosh Truck Corporation, Oshkosh, Wisconsin
RICHARD L. KEGG, Milacron, Inc. (retiredy, Cincinnati, Ohio
PRADEEP KHOSLA, Carnegie Mellon University, Pittsburgh, Pennsylvania
JAY LEE, University of Wisconsin, Milwaukee
JAM ES MATTICE, U n iversa I Tech nology Corporation, Dayton, Oh lo
MANISH MEHTA, National Center for Manufacturing Sciences, Ann Arbor, Michigan
ANGELO M. NINIVAGGI, JR., Plexus, Nampa, Idaho
H.M. REININGA, Rockwell Collins, Cedar Rapids, Iowa
LARRY RHOADES, Extrude Hone Corporation, Irwin, Pennsylvania
JAMES B. RICE, JR., Massachusetts Institute of Technology, Cambridge
ALFONSO VELOSA 111, Gartner, Inc., Portland, Oregon
JACK WHITE, Altarum, Ann Arbor, Michigan
JOEL SAMUEL YUDKEN, AFL-CIO, Washington, D.C.
Staff
TONI MARECHAUX, Director
vl
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Preface
Advanced energetic materials are a critical technology for the defense of the United
States. While many of these materials are routinely manufactured as commodities, several
new concepts and formulations have great promise for both evolutionary and revolutionary
applications. The Department of Defense is concerned with prioritization of scarce resources
as well as maintaining and improving the knowledge base in this area.
To help address these concerns, the Office of the Deputy Under Secretary of Defense
for Science and Technology and the Defense Threat Reduction Agency (formerly the Defense
Special Weapons Agency) requested that the National Research Council, through the Board
on Manufacturing and Engineering Design, conduct a study to investigate and assess the
scope and health of U.S. research and development efforts in energetic materials.
The Committee on Advanced Energetic Materials and Manufacturing Technologies (see
Appendix A) was charged with the following tasks:
Review U.S. research and development in advanced energetics being conducted by
the Department of Defense, the Department of Energy's national laboratories,
industry, and academia from a list provided by the sponsor of the study.
Review papers and technology assessments of non-U.S. work in advanced
energetics.
Assess important parameters, such as validity, viability, and the likelihood that each
of these materials can be produced in quantity. Identify barriers to scale-up and
production, and suggest technical approaches for addressing potential problems.
Suggest specific opportunities, strategies, and priorities for government sponsorship
of technologies and manufacturing process development.
The committee conducted five information-gathering meetings at which it received
presentations from the Department of Defense, the Department of Energy, and the Central
Intelligence Agency and from academic and industrial organizations (see Appendix B.
"Meeting Agendas"~. Additionally, committee members visited a representative group of
advanced development and production sites.
The committee effort focused on the following six major technical areas, defined by the
study's sponsor. Each is addressed in a separate chapter, following the Executive Summary
and an introductory Chapter 1.
vii
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· New energetic materials synthesis and development (Chapter 2),
· Thermobaric explosives (Chapter By,
· Reactive materia is (Cha pter 4),
· Nanomixtures and nanocomposites (Chapter by,
· Advanced gun propellants (Chapter 6), and
· Exotic physics (Chapter 7~.
Chapter 8 presents the major conclusions and recommendations of the study.
Findings and recommendations on the respective technical areas are presented in Chapters
2 through 7. A supplement to this report contains information that was determined by the
U.S. government to contain technical data whose export is restricted by the Arms Export
Control Act. Requests for the supplement should be made to ODUSD(S&T)/WS, Suite 9030'
1777 N. Kent St., Arlington, VA 22209.
The scope of this study covered a broad range of materials. The committee is
indebted to the experts who took the time to share their knowledge and insights. The
committee also greatly appreciates the support and assistance of National Research Council
staff members Sharon Young Dressen and Emily Ann Meyer in the development of this
report.
Ronald L. Atkins, Chair
Committee on Advanced Energetic Materials
and ManufacturingTechnologies
. . .
v///
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Acknowledgment of Reviewers
This report has been reviewed in draft form by individuals chosen for their diverse
perspectives and technical expertise, in accordance with procedures approved by the
National Research Council's (NRC's) Report Review Committee. The purpose of this
independent review is to provide candid and critical comments that will assist the institution
in making its published report as sound as possible and to ensure that the report meets
institutional standards for objectivity, evidence, and responsiveness to the study charge. The
review comments and draft manuscript remain confidential to protect the integrity of the
deliberative process. We wish to thank the following individuals for their review of this
report:
Robert Austin, Princeton University
George Dieter, University of Maryland
John W. Fischer, Naval Aviation, Science, and Technology Office
George Lester, Consultant
Fred Michel, Consultant
Hyla Napadensky, Napadensky Energetics, Ltd. (retired)
James O'Bryon, O'Bryon Group
La I itha Ra maswa my, U n iversity of Ma ryla nd
Alfred G. Stern, Naval Surface Warfare Center, Indian Head
Although the reviewers listed above have provided many constructive comments and
suggestions, they were not asked to endorse the conclusions or recommendations, nor did
they see the final draft of the report before its release. The review of this report was
overseen by Frank H. Stillinger of Princeton University. Appointed by the NRC, he was
responsible for making certain that an independent examination of this report was carried
out in accordance with institutional procedures and that all review comments were carefully
considered. Responsibility for the final content of this report rests entirely with the authoring
committee and the institution.
IX
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Contents
EXECUTIVE SUMMARY
1 INTRODUCTION
NEW ENERGETIC MATERIALS
Current Research Focus, 8
Transition Barriers, 9
Current CHNO/F Energetic Materials Research, 10
Cu rrent Transition to Applications, 14
Findings and Recommendations, 15
THERMOBARIC EXPLOSIVES
Current Focus, 16
Background and Current Research, 16
Transition Barriers, 18
Findings and Recommendations, 18
4 REACTIVE MATERIALS
Introduction, 20
Findings and Recommendations, 22
NANOMIXTURES AND NANOCOMPOSITES
Introduction and Current Research Activities, 24
Transition Challenges, 25
Ma n ufactu ri ng a nd Tra nsition Ba rriers, 26
Findings and Recommendations, 27
6 ADVANCED GUN PROPELLANTS
Current Research Focus, 28
Current Gun Propellants, 29
Advanced Gun Propellant Research, 30
Findings and Recommendations, 34
xl
1
5
8
16
20
24
28
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EXOTIC PHYSICS
Cu rrent Resea rch Efforts, 35
Findings and Recommendations, 36
8 MAJOR CONCLUSIONS AND RECOMMENDATIONS
APPEN DIXES
A BIOG RAPH ICAL SKETCH ES OF COM M ITTEE M EM BERS
B MEETING PRESENTATIONS AND SITE VISITS
C ACRONYMS AND ABBREVIATIONS
xii
35
37
40
45
49
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List of Tables and Figures
TABLES
6-1
6-2
FIGURES
1-1
4-3
6-1
6-2
6-3
6-4
6-5
Comparison of HMX and HNFX, 11
Comparison of Formulations for Propellant Materials, 29
Theoretical Benefits of Systems Using DANPE, 33
Molecular structures of selected energetic materials, 7
Damage done by inert fragments to the guidance component of a missile, 21
Damage done by reactive fragments to a guidance component identical to that
shown in Figure 4-1, 21
Damage done to a missile body by a warhead's inert fragments, 21
Damage done to the same target shown in Figure 4-3 by a warhead's reactive
fragments, 21
Calculated impetus and flame temperature for conventional (nitrocellulose (NC] and
nitrate esters ENE]) and thermoplastic elastomer (TPE) propellants, 30
Typical layered geometries of TPE propellants, 31
Pressure time trace from the firing of a 120-mm gun using layered TPE propellant, 31
Typical test setup for a pendulum test used to evaluate advanced layered propellant,
32
Slab extrusion using a twin screw extruder, 34
. .,
A/
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