DAHLGREN, Va. –
The spin rate and velocity of a projectile shot from a five-inch gun are so fast only a camera capturing 75,000 frames per second can freeze it mid-flight. At this speed, unseen phenomena become visible, revealing critical data that underpins the precision and impact of modern weapon systems. At Naval Surface Warfare Center Dahlgren Division (NSWCDD), these specialized cameras are essential for analyzing hypersonic projectiles and monitoring explosive dispersals. High-speed imaging transforms how we test, refine and deploy advanced military systems, ultimately safeguarding lives and empowering the Navy with precision and lethality.
The evolution of high-speed cameras at NSWCDD
When David Dukes, an Integrated Engagement Systems Department engineer, first began working in the field in 2006, high-speed cameras were significantly limited. Cameras then had minimal volatile random-access memory (RAM), a type of computer memory that requires power to retain the data, and could only record for fractions of seconds, with frame rates capped at approximately 3,000 frames per second (fps).
Today, those limitations are a distant memory. Modern high-speed cameras are equipped with gigabytes of RAM and can record for up to a minute, depending on the settings. They now achieve frame rates of 75,000 fps at maximum resolution, capturing high-definition footage of events previously invisible to the human eye. These technological leaps have opened the doors to precise real-time feedback during weapons development, allowing engineers to analyze vital data such as spin rates, projectile speed and explosive dispersal in intricate detail. “The benefit of the video footage is that subject matter experts at NSWCDD, who are working on prototype designs, can schedule tests on the Potomac River Test Range and make immediate adjustments based on the data provided by high-speed cameras,” said Duke.
Key applications of high-speed cameras in defense testing
Fragment tracking analysis at Explosive Experimental Area (EEA)
High-speed cameras are pivotal in analyzing explosions and fragment dispersion. At the EEA at Pumpkin Neck, VA, during arena tests or fragmentation studies, these systems track clusters of fragments, estimate their size and measure their velocity in unprecedented detail. Using pixel-based distance calculations, engineers can determine the impact zone with remarkable accuracy. Justin Stiltner, instrumentation engineer at EEA, highlighted that fragment tracking not only informs weapon safety but also aids in understanding the lethality and effectiveness of munitions. “The ammunition testing simulates real-world accidents, allowing for analysis of the events that occur in the milliseconds after an impact. By using high-speed camera data, we can understand what happened during that brief moment and how we can engineer solutions to prevent adverse reactions from occurring,” said Stiltner.
Hypersonic testing
The NSWCDD’s Hypersonic Integrated Test Facility utilizes high-speed cameras to analyze test rounds traveling at hypersonic velocities. Cameras operating normally at 8,000 fps capture crucial insights into the behavior of hypersonic projectiles, including their orientation upon impact and structural integrity mid-flight. This critical data informs design decisions for next-generation hypersonic weaponry, ensuring precision, reliability and maneuverability.
Ultra-high-speed cameras in recoil and dispersion tests
Another application of high-speed camera technology is the analysis of recoil and dispersion in ordnance testing. For instance, cameras help measure how far a gun recoils under specific conditions or analyze the dispersion pattern of munitions under stress. This data is invaluable when developing weapons that meet stringent performance criteria, especially for naval applications.
The challenges the team overcomes
While high-speed cameras offer revolutionary capabilities, their deployment comes with unique challenges. Lighting is often a critical factor. Ultra-high-speed frame rates reduce camera exposure time significantly, making robust external lighting essential. Traditional halogen and sodium lights typically dominated the field in earlier years, but modern LED lighting systems are now preferred, offering improved efficiency while addressing color distortion. However, more advancement in lighting systems must be made to contend with the enormous light requirements of ultra-high-speed applications.
Weather also presents major challenges to instrumentation engineers. Cameras must be protected from rain, wind and debris, all while maintaining functionality. Armor plating and bulletproof enclosures are often used to shield the hardware from the elements and the possible damaging effects created by the tests, ensuring data integrity.
Another significant hurdle is the limited depth of field (DOF) inherent to long focal-length lenses. DOF is the distance between the nearest and farthest objects that are in an acceptably sharp focus in a photographic image. Engineers often work with mere centimeters of focus range while tracking projectiles moving at extreme speeds. To mitigate these constraints, real-time adjustments and redundant camera setups are deployed to ensure critical shots are captured.
Collaborative relationships with camera manufacturers are instrumental in addressing challenges such as obsolescence and the need for light-sensitive sensors. The NSWCDD team holds regular discussions with vendors to stay ahead of market trends and secure technical support to meet current and future needs while addressing any challenges that may arise.
Data analysis and the warfighter advantage
Outside of the lab, insights from high-speed camera tests directly impact the warfighter. Securing ammunition requires testing rounds against real-world hazards, including high-impact drops, extreme temperatures and direct fire. High-speed cameras monitor these tests, capturing critical reactions, such as whether casings remain intact or if sabots separate cleanly.
The data also informs advanced modeling software used for operational planning. “High-speed footage helps engineers determine optimal angles, speeds and explosive forces for a range of munitions, ultimately enhancing performance in the field,” said Dukes.
High stakes and precision excellence
When testing prototype rounds that cost millions, every detail matters. Stiltner shared how the team at Dahlgren employs meticulous preparation to minimize risks. From redundant camera setups to mock tests and pre-shot checkouts, every step is designed to protect against data loss. The stakes are especially high when rounds are one-of-a-kind or when their success (or failure) directly impacts funding and program viability. This precision-driven culture allows the team to provide invaluable support to engineers and warfighters alike.
Future innovations on the horizon
The advancement of high-speed cameras remains an ongoing process. Looking ahead, NSWCDD engineers are exploring incorporating artificial intelligence (AI) into high-speed camera analytics. AI could enable automated tracking of fragments, real-time splash detection and advanced pattern recognition. While these capabilities are still conceptual, they represent a new area for future innovation.
The evolution of high-speed cameras signifies more than just a technical achievement; it represents a fundamental shift in how modern weapon systems are designed, tested and deployed. By offering a window into fleeting events that unfold in milliseconds, these cameras enable engineers to refine designs with unparalleled precision. Their application reaffirms a commitment to equipping warfighters with the best tools possible.
At Dahlgren, this commitment goes beyond capturing images. It is a tireless pursuit of excellence, driven by a mission to secure lives and deliver innovation to the Navy. For those at the forefront of high-speed imaging, every test is a step closer to unlocking greater possibilities for both military defense and scientific discovery.