IM EXPLOSIVE FOR SMAW HEAA WARHEAD N. C. Johnson, C. W. Gonzalez, K. W. Reed, L. A. Kowalczyk, W. L. Myers, V. L. Beam, V. A.

Fields Indian Head Division, Naval Surface Warfare Center Indian Head, MD ABSTRACT The Shoulder-Launched, Multi-Purpose Assault Weapon (SMAW) is an 83mm man-portable weapon system designed to fire a family of encased assault rockets (EARs), one of which is the High Explosive Anti-Armor (HEAA) rocket. The SMAW HEAA has a shaped charge warhead designed to defeat armor targets. Octol is the current warhead explosive fill. Octol is not an Insensitive Munition (IM) compliant explosive. The objective of the current effort is to replace Octol with an IM fill while retaining the current warhead performance for the SMAW HEAA rocket. INTRODUCTION Indian Head Division, Naval Surface Warfare Center (IHDIV,NSWC) was tasked by the Marine Corps Systems Commands Office of the Program Manager for Ammunition (PM Ammo) to replace the current SMAW HEAA warhead fill with an IM compliant explosive. The sponsors guidance was that there should be no loss in penetration performance and no change to the warhead should be made beyond replacement of the explosive composition. The SMAW is an 83 mm man-portable weapon system consisting of the MK 153 MOD 0 launcher with an integral spotting rifle, designed to fire a family of ammunition, one of which is the MK 6 MOD 0 HEAA EAR (DODIC HX-06). The HEAA rocket is effective against medium armor and most current tanks without additional armor. The launcher consists of a fiberglass launch tube (which is the rocket encasement), a 9 mm spotting rifle, and an electromechanical firing mechanism. The rocket without its encasement is illustrated in Figure 1. The rocket consists of three main components: a shaped charge warhead, an impact fuze, and the rocket motor.

Figure 1. SMAW HEAA Rocket Octol (HMX/TNT, 70/30) is the warhead main explosive. The explosive weight is approximately 1.9 pounds. A PBXN-5 booster (2 grams) is imbedded in the warhead closure. Because of its poor IM performance, Octol is not suitable for future Navy weapon systems. The current SMAW HEAA is expected to fail IM tests.1 A two phase approach was used to select the IM explosive replacement for Octol. In Phase I, a formal Explosive Selection Committee was convened to select potential explosives based on their IM properties and explosive output. Compositions considered were limited to DoD qualified explosives. Three explosive candidates were selected. They were loaded in the SMAW HEAA warhead and subjected to selected IM and penetration performance tests. Octol loaded warheads were also tested as a baseline. From the test data and warhead loading data, a final explosive composition was selected.

DISTRIBUTION STATEMENT A: Approved for Public Release. Distribution is unlimited.

The selected composition is being taken forward into Phase II where the SMAW HEAA warhead with the IM fill is being put through qualification and performance tests to ensure that the system is safe and will meet system performance requirements. RESULTS AND DISCUSSION EXPLOSIVE SELECTION COMMITTEE The Explosive Selection Committee compared DoD qualified explosives based on explosive output and expected warhead effectiveness, IM survivability in generic or specific weapon hardware, safety and reliability data, and life cycle costs. The highest weighted factor in accordance with the sponsors direction was penetration performance. The compositions selected for evaluation in the SMAW HEAA warhead were PBXN-9, PBXN-11, and PBXW-114. The properties of these compositions along with the Octol baseline are listed in Table 1. PBXN-9 and PBXN-11 are among the best performing and safest qualified pressed explosives. PBXW-114 was selected as an insensitive cast explosive that has performance comparable to PBXN-110 and PBXN-112 and, therefore, would be expected to have nearly equal penetration performance. PBXW-114 offers the added benefit of being more likely to pass the fragment impact test.

Explosive

Composition

Manufacture Method

Density, g/cc FCO/SCO/BI

PBXN-9

HMX/binder

pressed

1.73

V/V/V

PBXN-11

HMX/binder

pressed

1.80

V/V/IV

PBXW-114

HMX/Al/binder

Octol

HMX/TNT

cast melt (sedimentation) cast

1.71

V/V/V

1.82

I/I/V

Table 1. Properties of the Explosive Candidates and Octol Baseline

PHASE I TESTS SMAW HEAA warheads were loaded by IHDIV, NSWC with PBXN-9, PBXN-11, and PBXW-114. Copper shaped charge liners from the 1990s SMAW HEAA production contract were used. Several liners were inspected to verify that they met material and dimensional requirements. Warhead and rocket components used for Phase I tests were a combination of parts left from the production contract and parts procured using the SMAW HEAA technical data package. Octol loaded warheads from the production contract were used as a baseline for data comparison. SMAW HEAA warheads were subjected to slow cook-off and fragment impact testing. These tests are typically the hardest IM tests to pass. Static penetration tests were conducted to evaluate penetration depth against RHA. Problems were encountered loading PBXN-11 in the SMAW HEAA warhead. Unlike PBXN-9 molding powder, the PBXN-11 powder did not consolidate at comparable press pressure to achieve the high density required for a shaped charge warhead. This is probably due to the fact that PBXN-11 has half the binder coating of PBXN-9 and does not flow the same under load. This lack of PBXN-11 flow results in transfer of the consolidation force into more compression loading of the warhead case (as

compared with PBXN-9), and subsequent case deformation. Several approaches were tried during Phase I, but more work is necessary to improve the PBXN-11 loading process. PHASE I TEST RESULTS Slow cook-off, fragment impact, and warhead static penetration tests were performed by Dahlgren Division, Naval Surface Warfare Center. Two slow cook-off tests were conducted for each explosive fill. The tests were performed in accordance with MIL-STD 2105C and STANAG 4382. The test configuration was a live warhead and live booster. Inert mass simulates were used for the remaining rocket components so that confinement of the warhead would be realistically approximated and so that the rocket motor response would not mask the response of the warhead. The SMAW rocket motor detonates in slow cook-off. It was thought that the absence of the rocket encasement would not affect the outcome of the test. The test item configuration is shown in Figure 2. Thermocouples (TCs) were placed on the test item to record temperature. Results of the test were: deflagration for PBXN-9, burn for PBXN-11, deflagration for PBXW-114, and detonation for the Octol baseline. The liner was ejected from the warhead in all of the candidate explosive slow cook-off tests.

Figure 2. Slow Cook-Off Set-up Two fragment impact tests were performed for each explosive fill. Testing was conducted using the procedures of MIL-STD-2105C and STANAG 4496. The test configuration was live warhead and live booster. Inert mass simulates were used for the remaining rocket components so that confinement of the warhead would be realistically approximated and so that the rocket motor response would not mask the response of the warhead. The test item configuration is shown in Figure 3. The fragment velocity for the first test for each composition was approximately 8000 feet per second. The fragment velocity for the second test for each explosive composition was approximately 6000 feet per second. The test results were: detonation for both PBXN-9, both PBXN-11, and Octol tests. The PBXW-114 loaded warhead detonated at the higher fragment velocity and displayed a deflagration reaction at the slower velocity.

Figure 3. Fragment Impact Test Set-up

Warhead penetration tests were conducted in accordance with the procedure provided in the SMAW HEAA warhead weapon specification.2 Three penetration shots were conducted for each composition except for PBXN-11.

There was considerable variation in the penetration data for each composition. Only one Octol shot met the penetration requirement. One PBXW-114 shot barely met the minimum requirement, the other shots fell well short. All three PBXN-9 shots met the requirement. Only two PBXN-11 charges were available for testing due to loading problems. One was a low density charge. Penetration performance of the high density PBXN-11 charge exceeded that of the three PBXN-9 charges. Penetration of the low density charge was within the requirement. Phase I results are summarized in Table 2.
Current Loadability IM Reactions Penetration SCO Passed Passed Failed IV (2)
Deflagration

Explosive

Density 1.744 1.744 1.750 1.769 * 1.803 ~1.71

Frag Impact
(T1 8000 ft/sec, T2 6000 ft/sec)

PBXN-9 PBXN-11 PBXW-114 Octol (baseline)

Yes No Yes

I (2) Detonation I (2) Detonation I (1)

Detonation

V (2) Burn IV (2)

Deflagration

IV (1)
Deflagration

1.80-1.85

N/A

Failed

I (2) Detonation

I (2) Detonation

* 98% TMD is 1.793 gm/cc. 1.769 is 96.7% TMD

Table 2. Summary of Phase I Results PBXN-9 was selected as the IM explosive for the SMAW HEAA warhead. PBXN-9 exceeded the SMAW HEAA warhead penetration requirement and performed better than the Octol baseline in the limited number of tests that were performed. The PBXN-9 slow cook-off response was milder than that of the Octol warhead. PBXN-9 is fielded as the main charge explosive in other shaped charge warheads. In summary, based on the combination of warhead penetration performance, SCO results, and ease of loading the warheads, PBXN-9 was selected as the IM explosive to take forward in Phase II for qualification and performance tests. A barrier tape (e.g., 4 mil aluminum tape) will be placed between the PBXN-9 charge and the PBXN-5 booster to avoid migration of dioctyl adipate (DOA) plasticizer from the explosive fill into the PBXN-5 and desensitizing it. [This change would have been required for any of the candidate explosives since they all contain a mobile plasticizer.] PHASE II QUALIFICATION AND PERFORMANCE TESTS SMAW HEAA with PBXN-9 warhead fill is being unofficially called SMAW HEAA-IM Warhead until qualification and performance tests have been completed. The objectives of these tests are to verify that replacement of the warhead explosive fill has not caused degradation of SMAW HEAA system performance, to ensure that the SMAW HEAA-IM Warhead meets IM and Hazard Classification requirements, and to obtain Final (Type) Qualification for the SMAW HEAA-IM Warhead system. IHDIV, NSWC contracted with Nammo Talley Inc. to build the SMAW HEAA-IM Warhead test items. The warhead shaped charge liners are from the 1990s SMAW HEAA production program and were provided as government furnished material. The liners were inspected for conformance to the SMAW HEAA technical data package. Deviations were noted. Mk 259 fuzes were obtained from inventory as government furnished material. Warheads were loaded with PBXN-9 main charge fill and PBXN-5 booster explosive by IHDIV, NSWC. The qualification and performance testing will be conducted by National Technical Systems (NTS), Camden, Arkansas. Testing is scheduled for March-June 2009.

The tests to be performed are listed in Table 3. The tests have been harmonized for IM and hazard classification, but include only a limited subset of the full qualification suite of tests since this effort is changing only the warhead explosive fill and not any safety features of the system.
Configuration 28-day T&H, Thermal Stability, Vibration, 4-day T&H, 40 ft. drop Shipping 28-day T&H, Thermal Configuration Stability, Vibration, 4-day T&H, Flight Performance Testing Flight Performance Testing (Baseline) EAR EAR Live WH w/Booster 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Rocket Motor Live Inert 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Spotting Round Fuze Live Inert Live None 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Shipping Sympathetic Detonation Configuration Confined Stack Test

Sympathetic Detonation Shipping Unconfined Stack Test Configuration

Fast Cook Off

Shipping Configuration

Fast Cook Off Slow Cook-Off Bullet Impact Fragment Impact 3 Month Aging, Penetration Testing 6 Month Aging, Penetration Testing Vibration, Penetration Testing Baseline Penetration Testing

EAR EAR EAR EAR EAR EAR EAR WH only WH only WH only WH only WH only WH only WH only WH only WH only WH only

Table 3. Test Matrix for SMAW HEAA-IM Warhead Qualification and Performance Tests

SUMMARY AND CONCLUSIONS PBXN-9 was selected as the IM explosive fill replacement for Octol in the SMAW HEAA warhead based on a combination of IM, warhead performance, and loading results. Qualification and performance testing of the SMAW HEAA-IM Warhead is underway. Results of these tests will be presented at a later time. REFERENCES 1. 2007 Marine Corps IM Strategic Plan. 2. WS-22462K, MATERIAL SPECIFICATION FOR WARHEAD, HEAA, (SMAW), MARK 124 MOD 0