Objective:

The Department of Defense (DoD) has recognized heavy metal contamination as a critical environmental problem and assumed responsibility for reducing the use of lead and other contaminants in munitions. This project was established to demonstrate a process capable of producing Ultra-Fine Aluminum (UFAL) in sufficient quantities to support production of small caliber percussion primers. The feasibility of Metastable Intermolecular Compound (MIC) compositions for percussion primers was successfully demonstrated in SERDP Project PP-1057. In lieu of the conventional lead styphnate and barium nitrate mixture, MIC compounds represent a new class of energetic composed of ultra-fine particle-sized mixtures of metal/metal oxides that retain the high temperature and large release of heat associated with thermites but burn at a much faster rate, making them suitable for primer compositions.

Technology Description:

The main technical hurdle in the development of MIC-based percussion primers has been the ability to manufacture UFAL at rates greater than 50 grams per hour; however, with the recent availability of commercial grade UFAL from various sources, the goal of the project was redirected to reformulate the MIC composition utilizing commercial UFAL. Based on the NAVAIR-funded study that optimized the MIC oxidizer, a common formulation to satisfy the requirements for the Army’s small caliber percussion primers and the Navy’s application for Cartridge Activated Devices will be established. A tier I and II toxicology evaluation will be performed to validate current industrial material safety data sheets (MSDS). As scale-up from laboratory-sized mixing to larger bulk quantities (50 grams per hour), this project will establish the safe bulk handling requirements for intermediate scale-up fabrication quantities. At the conclusion of this effort, the MIC-based materials will be demonstrated as 41 primers in ballistic testing of small caliber 5.56-millimeter cartridges and in simulated application of Cartridge Activated Devices.

Expected Benefits:

The successful completion of the development of a MIC primer will remove a major source of airborne lead pollution from DoD firing ranges, test facilities, and military operations. This action will reduce health risks to all personnel engaged in these operations and will help to reduce the need for range cleanup and remediation. Furthermore, the DoD will avoid potentially critical shortages of percussion primers for ammunition, which are certain to result if lead-free replacements are not found. (Anticipated Project Completion - 2006)