Rapid High Pressure Combustion Driven Powder Consolidation for the Development of Reactive Fragments and their Dynamic Properties

The major objectives of the Phase I effort will be focused on CDC high pressure compaction/fabrication, post-processing, testing and materials performance/baseline preliminary material modeling of the kinetic behavior of the energetic material compositions based on select geometry and CDC materials properties. CDC compacted candidate reactive fragment warhead/projectile materials include Hf/Al, W/Al, Al/Boron, Hf/Zn, Zr/Zn, Zr/Al, or Ta/Al, Mo/Al, and select materials with boron, molybdenum oxide and/or sulfur. Select geometrical shapes such as 0.5 inch diameter cylinders/disks, near spheroidal pellet shapes (e.g., 0.5 inch diameter), and 3.5 inch long tensile dogbones will be fabricated using the available 300 ton CDC press and existing die/punch assemblies for initial exploration. Compositions will be optimized in consultation with OSD sponsors to obtain densities closer to 7 g/cc or higher. Appropriate experimental process optimization at much higher compaction pressures (e.g., 50 to 150 tsi) will be developed as an integral part of Phase I and Phase II. Key CDC process optimization, suitable sintering/heat treatment responses, near or net shaped reactive fragments/warhead spheroidal pellet part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength durability properties at room temperature will be evaluated in Phase I. In Phase II, scaling up, materials/manufacturing of reactive fragment warhead components such as multiple-pressing of several spheroidal shaped warheads etc will be planned and the developed CDC parts after optimum processing conditions.