Active Projects
N,N’-Di-2-naphthyl-p-phenylenediamine (DNPD) is a component of the antioxidant package used in air-to-air missile propellants, including the AIM-120 Advanced Medium Range Air-to-Air Missile. DNPD is the primary antioxidant in this propellant, working to maximize propellant shelf life by inhibiting oxidation of the binder network. A continental United Status (CONUS) source of DNPD has not existed since its U.S. manufacturer discontinued the product. Production of propellant using DNPD has proceeded with outside the continental United States (OCONUS)-sourced material since then.
The objective of this EMTC project was to develop and scale up a cost-effective method for synthesis and purification of DNPD that meets customer material specification HS 6-0089A. A further objective was to establish a reliable, CONUS-based source for DNPD of consistent quality and availability for propellant production. If such a source were established, DNPD may become the antioxidant of choice for next-generation propellants owing to its combination of performance, price and availability. To learn more, read Source of DNPD Antioxidant Manufacturing Capability (PDF).
The objective of this EMTC effort was to enable the advanced manufacture of U.S. Navy/U.S. Marine Corps critical, solid propellant grains for use in cartridge actuated devices (CADs) and propulsion systems. Additive manufacturing (AM) is an advanced manufacturing technology that has the potential to produce lower cost propellant grains with little-to-no induced thermal stress/strain during cure. Under this effort, two types of AM technology were explored for use in propellant manufacturing: material extrusion and vat photo-polymerization. Adaptation of these AM technologies for energetics will enable both composite and single- and double-base forms of propellants to be manufactured using advanced techniques. To learn more, read Enabling the Advanced Manufacture of Propellants (PDF).
Many of the currently fielded air- and surface-launched Navy missile programs were initially developed 20-30 years ago. As such, these programs may experience material-related issues including material obsolescence, discontinued products, inconsistent quality or characteristics of material from manufacturers and diminished manufacturing sources.
These issues make it necessary for alternate materials and/or sources to be identified to perform the same or similar function as the material being replaced. In some instances, a modification of a formulation may be necessary in order to allow systems to continue to be manufactured without interruption. Any formulation modifications would need to be evaluated in advance so that the necessary changes can be made without program interruption.
The established process for the production of hexanitrostilbene (HNS) is the classic one-step Shipp procedure. The Shipp process typically produces a crude yield of 30-55 percent that requires further purification and results in even lower overall yield. A two-step process for small-scale synthesis of HNS is also reported. The first step is the synthesis of the intermediate hexanitrobibenzyl (HNBB) and the second step is the oxidation of HNBB to HNS. The objective of this work was to optimize the two-step process in such a way that a large-scale synthesis of HNS becomes feasible and cost effective. This will provide the Navy and the Department of Defense with a reliable CONUS source of HNS. To learn more, read Source of HNS Manufacturing Capability (PDF).
The objectives of this EMTC project are to demonstrate and qualify a novel initiating explosive for use in ultra-low energy exploding foil initiators (𝜇LEEFI) and then demonstrate and qualify a novel ultra-low energy initiator. The warfighter needs lightweight, safe and reliable initiation systems. This technology is an enabler for future smart weapons when employed in multi-point configurations that facilitate directional, deformable and tailorable effects warheads, as well as inclusion in smaller smart munitions that may currently employ out-of-line devices and hot wire detonators. Future in-line safe initiation systems must consume less energy, volume and weight. This state-of-the-art explosives technology can meet the requirement for smaller, less energy-intensive systems.
The 𝜇LEEFI is a qualified in-line initiator (ILI) permitted for use without interruption. Advancements in ILI technology are required to enable much smaller initiation systems with lower energy demands. This project will demonstrate 𝜇LEEFI technology enabled by the use of sub-micron CL-20 harvested from industrial grinds of CL-20. To learn more, read Novel Initiating Explosive for Use in u-LEEFI (PDF).
The objective of this Energetics Manufacturing Technology Center (EMTC) project is to provide a modular agile system for the synthesis and crystallization of energetic materials called the Continuous Acoustic Reactor / Continuous Acoustic Crystallizer (CACR /C AC). The design work will be predicated on the synthesis and crystallization of 2.6-diaminopyrazine-1-oxide (DAPO), a precursor to LLM-105 from N-nitrosodi (cyanomethyl) amine (IDAN-NO). The ultimate objectives are to design, build, and install a system capable of producing a variety of energetic materials.
Multiple energetic materials may be synthesized and/or crystallized. The actual materials, apart from the designed bases DAPO and IDAN-NO, are yet to be determined. The CACR / CAC has the ability to process solid materials up to 200 microns in size in a liquid stream. This is a feature that is an improvement over alternatives such as an Advanced Flow Reactor (AFR). Solid precipitates form during energetics synthesis and plug the flow path of an AFR. Additionally, tunable crystallization allows control of particle size and distribution to desired parameters.
Resodyn will design and build the prototype for the CACR / CAC as well as assist in installing the equipment at Naval Surface Warfare Center Indian Head Division (NSWC IHD). To learn more, read RAM Technology for Energetics Synthesis and Crystallization (PDF).
The availability of energetic materials (explosives, propellants, and pyrotechnics) and the constituents required to make them is a major readiness issue for the Navy. Aging manufacturing infrastructure, foreign dependency, fragile supply chains, diminishing domestic suppliers, increasing environmental regulations, unique material specifications, and reduced demand increase the risk within the Navy acquisition community for the development and procurement of weapon systems. Mitigation of these issues makes it necessary to identify alternate materials and suppliers or to create an organic manufacturing capability to produce the critical materials. In many cases, new manufacturing technology is required to make the process viable, affordable, and sustainable.
By providing an increased awareness of Navy supply chain issues, this study identified opportunities to eliminate dependency on foreign or adversarial sources, evaluate capacity and surge requirements, and implement process recommendations for improved transition of new materials into acquisition programs. It established a proof-of-concept supply chain management tool that allowed for data-driven decision-making for project selection and future Navy capital investments. This tool facilitated future supply chain risk management and participation in DoD energetics supply chain risk mitigation efforts, effective leveraging of other DoD and Service investments, and improved acquisition planning to ensure defense industrial base health/sustainment, replenishment, and surge capacity. To learn more, read Supply Chain Resilience = Mission Readiness! (PDF).
The objective of this Energetics Manufacturing Technology Center (EMTC) project is to provide a system that will permit the continuous post-treatment of energetic materials from a Corning G1 Advanced Flow Reactor (AFR). The system will be designed to quench and purify methyl / ethyl nitratoethylnitramine (NENA) but will be suitable for use with a variety of liquid energetic materials.
The Navy requires an on-demand capability for production and purification of liquid energetic plasticizers (NENAs) that are more stable and less sensitive than nitroglycerin. This project aims to develop a post-processor that will meet that need. The design will be based on the synthesis and purification of methyl / ethyl NENA, although other energetics materials may be synthesized. The use of the Corning G1 AFR for upstream production (developed under a previous EMTC effort with Nalas Engineering) in combination with an automated downstream quench, neutralization, and separation unit (this effort, with Synthio Chemicals), allows for continuous production of NENAs. This approach offers improved heat transfer, finer control over product quality, and a smaller energetics footprint (less energetic material in one physical processing unit) as compared to a Continuously Stirred Tank Reactor (CSTR). Multiple liquid energetic materials may be purified and processed through this system. While the equipment configuration is based on the synthesis of methyl / ethyl NENA, other energetic materials may be synthesized using the post-processor with agile modular design. To learn more, read S2995 Continuous Post Processing for Methyl/Ethyl NENA (PDF).
Energetics are among the longest lead items for munition production, which significantly delays their delivery to the warfighter. Lack of supply chain transparency from materials procurement interferes with Energetics Manufacturing Technology Center’s (EMTC’s) ability to mitigate critical energetic material issues. The project objective is to refine and expand the proof-of-concept Navy Industrial Base Assessment Tool (N-IBAT) into a functional prototype and demonstrate its capabilities, which will help EMTC improve acquisition readiness, meet sustainment requirements, and meet emerging performance requirements for PEO / PM / prime contractor transition.
Iterative testing of N-IBAT will be done in close collaboration with Decision Sciences Incorporated to develop the N-IBAT into a functional tool with data storage, analysis, retention, update, and retrieval capabilities for tracking Navy energetic supply chains. Data will continue to be organized and added into the N-IBAT database so that periodic updates can be performed to monitor changes in the supply chain and identify future needed efforts.
The N-IBAT has benefactors across several levels. It will aid EMTC in tracking manufacturing data and developing investment strategies for critical chemicals. Stakeholders, such as Assistant Secretary of the Navy for Research, Development, and Acquisition, Deputy Assistant Secretary of Sustainment, and Navy PEOs and PMs benefit from the database because it will improve their supply chain risk planning and provide increased awareness of Navy supply chain issues. By integrating the N-IBAT with other DoD supply chain management systems, DoD can then use the joint IBAT to perform supply chain risk planning across all DoD weapons acquisitions. It is possible that the N-IBAT will improve the effectiveness of leveraging DoD investments, including Innovation, Capability, and Modernization (ICAM), the Defense Production Act Title III, and the Manufacturing Science and Technology Program. This tool can maintain a more robust industrial base to support future energetic material (EM) requirements because it can provide insights that will help suppliers’ better address government needs and facilitate planning for efficient incorporation of novel manufacturing technologies into the supply chain. To learn more, read S3026 — Navy Industrial Base Assessment Tool (IBAT) for Critical Chemicals (PDF).
Many of the currently fielded naval underwater weapons programs require materials that do not have reliable Continental United States (CONUS) sources and the underwater explosive (UNDEX) formulations for those systems are in need of updating. These programs are continually faced with material-related issues due to: 1) material obsolescence – current qualified supplier(s) have discontinued products or product lines; 2) the quality or characteristics of material coming from current manufacturers is inconsistent; and/or 3) critical materials only have a sole-source point of domestic manufacture. In many instances the materials that are being discontinued are no longer available from alternate domestic manufacturers.
The Energetics Manufacturing Technology Center (EMTC) will support the chemical scale-up team at Naval Surface Warfare Center Indian Head Division (NSWC IHD) with the manufacturing of the L-series energetic products: L721, M1L721*6H2O, M1L721*4NH3, and L725. Although a certified lab-scale process from the inert precursor, L701 to L721 has been submitted before, prior attempts at scale-up of the process proved difficult and inefficient. In collaboration with the Naval Research Laboratory and Combat Capabilities Development Command Armaments Center, EMTC is designing and executing modern scalable processes for these selected L-series materials that can be fitted for pilot-scale production. To learn more, read Scale-up of L-series Materials for CONUS Explosive Fills (PDF).