Studies on the Effect of Ageing on a
range of UK Polymer Bonded
Explosives
Philip Cheese, Peter Barnes, Michael Sharp
DOSG
Ron Hollands and Ian Murray
BAE Systems
Nigel Davies and Peter Jemmet
RMCS Shrivenham
Ageing and Insensitive Munitions
y Many cast PBXs have very good IM
properties when pristine - low sensitiveness
and explosiveness
y Ageing is known to affect the mechanical
properties of the polymeric matrix of cast-
cured PBXs
y There is a need to establish that the IM
capability of cast PBXs is not compromised
during service life
UK programmes on ageing of
cast PBXs
y Accelerated ageing of cast PBX samples to
simulate 20 years service life.
y Mechanical, chemical and hazard testing of
aged and control samples
– What changes?
– By how much?
– Does this change compromise IM?
y Environmental trials on PBX-filled munitions
Explosives studied
Composition Nominal Formulations (%m/m)
RDX Aluminium HTPB Plasticiser
(isocyanate cured)
ROWANEX 1100 88 -- 5 7
ROWANEX 1400 66 22 5 7
y Rowanex 1100 is BAE Systems’ explosive of
choice for future artillery and general purpose
systems
y Rowanex 1400 is an optimised blast
explosive
Ageing programme for
environmentally conditioned
Rowanex 1400 samples
Step Environmental Conditions
1 31 days at 71°C
2 169 days B3 cycling (diurnal cycle 33-71°C)
3 Transport Vibration (Def. Stan. 00-35; 2hr per axis, 2g sinusoidal sweep)
4 10hr vibration per axis ((Def. Stan; 00-35 -0.4g2/Hz, 20-2000Hz)
5 Thermal Shock (Def. Stan. 00-35; +70 to -55°C, transfer time 3-5min, 10
cycles)
y Represents nominal 20 year service life
y Radiography indicates no change in
frequency of voids between control and aged
test pieces
Test Regime for Control and Aged
Samples of ROWANEX 1400
Test or Method Specification or Reference
Antioxidant level STANAG 4581
Sol / Gel QinetiQ/FST/LP033918 / STANAG 4581
Moisture content Memo dated 30/03/2004
Dynamic mechanical analysis STANAG 4540
Surface hardness From guidelines given in BS 903-A26:1995,
ISO 48:1994 and BS 903-A57:1997, ISO
7619:1997, LP043948.
Tensile testing STANAG 4506
Heat flow calorimeter STANAG 4582
Tube test - internal ignition version EMTAP No.35
Tube test -Fuel fire version EMTAP No.41
Tube test -Electrically heated version EMTAP No.42
Large scale gap test EMTAP No.22
Additional Non-standard Tests
Test method Additional Diagnostics or Tests
Dynamic mechanical analysis Ultrasonic analysis, SEM
Chemical Analysis GC-MS, Thermal Analysis (DSC, TGA), IR
Spectroscopy
Instrumented Gap Test
Chemical and mechanical test results
for environmentally conditioned
samples
Test Notes Conclusions
Soluble Fraction Results distribution greater for aged
samples
Antioxidant Levels Slight Reduction on Ageing
Moisture content Karl Fischer method and weight No Significant
loss on vacuum heating Changes
Shore A Surface Hardness No Significant
Changes
Dynamic Mechanical Analysis (DMA) .
0.6
Unaged 2-9
Unaged 2-10
Aged 3-9 0.5
Aged 3-10
0.4
tan_delta (
[]
0.3
)
0.2
0.1
0.0
-150.0 -100.0 -50.0 0.0 50.0 100.0
Temp [°C]
y Small increase in modulus between about -80 and -50oC
y Glass transition temperature remains unchanged at -95oC.
Tensile Test results, Comparison of Maximum
Stress Level
0.7
Control
Aged
0.6
0.5
0.4
0.3
0.2
0.1
0
-40°C 20°C 60°C
y Relatively small changes at low and ambient temperature
y Reduced maximum stress and modulus, increased strain
capability
Max load before failure at 60°C
0.05
Max Load / kN
0.04
0.03
0 1 2 3 4 5
Age / months
y Significant increase in the strength of the PBX over the first
month of ageing, presumably due to the continuing cross-linking
reaction.
y Elasticity also increases on ageing
Compression Testing
2
Unaged
1.5 Aged 1mth at 60oC
Load / kN
Aged 2 mths at 60o C
1 Aged 3 mths at 60o C
Aged 4 mths at 60o C
0.5
0
0 2 4 6 8 10
Displacement / mm
y Little variation in the load required to cause plastic deformation
as the material ages.
y Homogeneity of filler dispersion within the matrix would account
for the slight variations in compression resistance.
Acoustic Analysis
Velocity of Sound = 1666ms-1
- has remained constant for the samples tested
Height of Reflected Signal /
32
30
28
mm
26
24
22
20
0 1 2 3 4 5 6
Age / mths
Signal attenuation is reduced with age. Less energy
lost to elastic polymer as X-linking increases
ATR/IR Transmission
Transmission
Data C-H
polymer
Transmission / Reflectance
C-H RDX
100
90
80
70
ATR Data 60
50
40
30
-1
20
Urethane peak @ 1737cm 10
0
4000 3600 3200 2800 2400 2000 1600 1200 800 400 0
Wavenumber / cm-1
IR Peak Ratios
Urethane/C-HRDX
Urethane/C-Hpolymer
1.4
1.2
1.0
Ratio
ATR
0.8
0.6
0.4
Transmission
0.2
0 1 2 3 4
Age / Months
y Intensity of urethane peaks is reduced with age
y Can be explained by the formation of allophanate groups?
Vacuum Stability
y Carried out in accordance with STANAG 4147
y Samples heated at 80°C for 10 days
Pressure / mbar
600
500
400
Tube 1
300
Tube 2
200
100
0
0 2 4 6 8 10
Time / days
Large Scale Gap Test
Sample Median gap Median Gap
(mm Perspex) (Gpa)
Control 33.5 4.38
Aged 33.9 4.29
LX-14 54.4 1.70
Rowanex 44.8 2.50
1100
Tube Test - Internal Ignition
y Control
– 8 no ignition
– 2 burned, no burst
y Aged
– 3 no ignition
– 4 burned, no burst
– 3 burst, no fragmentation
Tube Test - Fuel Fire
y Control
– 4 burst, no fragments
– 6 deflagration, maximum 4 fragments
y Aged
– 3 burst, no fragments
– 7 deflagration, maximum 4 fragments
Conclusions for Rowanex 1400
y Chemical and physical properties change
with age
y These changes are not sufficient to
compromise IM capability
y Values measured can be used as bounds for
intelligent surveillance programmes
Environmental Trials on PBX-
filled Munitions
y BAE Systems has carried out risk reduction
programmes on a range of ROWANEX 1100
filled projectiles, in readiness for anticipated
UK MOD orders for IM compliant ammunition
systems:
– L15 155mm
– L31 105mm HE
– 4.5” IA/IM Naval Ammunition
155mm L15 Projectiles
y Bounce to Defence Standard 00/35, Test M11,
duration 6 x 5 minutes
y Modified AOP-34 vibration regime (AS90),
205minutes duration low frequency at axial
and traverse, and 44 minutes duration high
frequency at axial and traverse
y 2.1m drop to Defence Standard 00/35, Test
M5, two drops per shell
y All At –46°C
155mm L15 Projectiles
155mm L15 Cold Bounce
155mm L15 Cold Drop
No evidence of cracking, exudation or dusting
105mm L31 Projectiles
y Sixty shell conditioned; thirty at –46°C and
thirty at +63°C
– 2.1m drop to Defence Standard 00/35, Test M5,
two drops per shell
– Loose cargo bounce to STANAG 4370, AECTP-
400 Method 406, duration 2 x 10 minutes
– 7 days B3 Diurnal Cycling to STANAG 2895
y All fired without incident at pressures up to
400MPa
4.5” IA/IM Naval Ammunition
y 15 rounds were conditioned at –18° and
+49°C packed in N36 containers/N6 crate
– Logistic vibration to Defence Standard 00-35, Test M1 for 6 hours
– Restrained cargo shock to Defence Standard 00-35, Test M3
– Multiple free fall to Defence Standard 00-35, Test M5; two from 1.5m while
cold and one from 2.1m while hot
– Horizontal impact to Defence Standard 00-35, Test M5
– B2 Diurnal cycling for 91 days (equivalent to 3 years service) and 231 days
(equivalent to 10 years service)
– C1 Diurnal cycling for 14 days
– Free fall to Defence Standard 00-35, Test M5, either 1m, 1.5m or 2.1m
– Ship vibration to AECTP Edition 1, Method 401
– Underwater shock to Defence Standard 00-35, Test M3
– Free fall to Defence Standard 00-35, Test M5, 0.5m
4.5” IA/IM gun firings
– After completion of the three year environmental
regime five rounds were fitted with L106 fuzes and
gun-fired without incident.
– After completion of the ten year environmental
regime five rounds were filled with NC23 fuzes
and gun-fired without incident.
Conclusions for Rowanex 1100
y Extensive accelerated ageing has failed to
induce any apparent failure in Rowanex 1100
filled shell
y Aged shell proven to be safe for gun launch
y Although mechanical properties undoubtedly
change with time, there is no reason to
suspect that this could compromise the
excellent IM characteristics of the formulation
Questions?
