TITLE: Algorithm Development for Assessment of Energetic Materials under Vibration Exposure
TECHNOLOGY AREA(S): Space
ACQUISITION PROGRAM: JSF
Joint Strike Fighter
OBJECTIVE: Develop a
physics-based algorithm for assessment of energetic material wear, failure, and
decomposition while under vibration exposure for use in compressing service
life vibration phenomena into an equivalent laboratory test.
Vibration-induced stress and associated wear accumulation over time, as a
result of the platform carriage environment, is one of the reasons weapon
systems can fail to perform their intended function. In terms of evaluating the
effects of the service-use vibration environment on weapon systems, it is
preferable to conduct laboratory vibration testing in real-time to most
effectively assess exposure consequences. However, in most instances, real-time
testing cannot be justified based on cost and/or schedule constraints;
therefore, it is common practice to compress the service life vibration
environment into an equivalent laboratory test.
For vibration environments, which vary in severity throughout the service life
of the weapon, the duration of the laboratory test environment can be reduced
by scaling the less severe segments of the service use vibration environment to
the maximum levels of the service use environment through use of an acceptable
algorithm. If metal fatigue is a significant potential failure criterion for
the weapon system within its service use environment, laboratory testing of the
weapon system using maximum service use vibration levels to compress test times
is an acceptable practice within strict limits; namely, test amplitudes should
not be over-exaggerated / accelerated merely to achieve short test durations.
Excessive laboratory test amplitudes may lead to unrepresentative failures, and
create extreme design requirements rather than designing to actual in-service
conditions, resulting in additional program cost or even program failure.
The most commonly used method for calculating a reduction in laboratory
vibration test duration is the Miner Palmgren hypothesis which uses a
fatigue-based power law relationship to relate exposure time and amplitude. The
Miner Palmgren algorithm is based on metal fatigue only and does not support assessment
of weapon system energetic materials (e.g., warhead explosives and rocket motor
propellants). Because a laboratory vibration test compression algorithm does
not exist for energetic material, current practice within industry and the DoD
is to assess energetic materials under laboratory vibration test conditions
using the Miner Palmgren algorithm. It is well understood by the energetic
technical area expert (TAE) community that use of the Miner Palmgren algorithm
is highly insufficient for energetic assessment of vibration exposure, and
could result in erroneous service use suitability decisions leading to loss of
life and equipment and failure to accomplish mission objectives.
PHASE I: Design, develop, and
demonstrate feasibility of a physics-based algorithm for assessment of
energetic material wear, failure, and decomposition while under vibration
exposure for use in compressing service life vibration phenomena into an
equivalent laboratory test. Conduct a feasibility assessment that will include
identification and characterization of energetic material properties required
for input to the algorithm. Sample materials will be available to Phase I
awardees. Develop prototype plans to be developed under Phase II.
PHASE II: Based upon the
results of Phase I, develop a prototype algorithm and validate its capability
through analytical and experimental demonstrations. Analyses and experimental
results should predict and validate wear, failure, and decomposition failure
PHASE III DUAL USE APPLICATIONS:
Conduct a full-scale vibration test on a tactical weapon energetic system such
as a warhead or rocket motor. Conduct testing in at least two separate case
scenarios: e.g., one test case will introduce an induced failure mode that can
be progressively tracked and validated throughout testing; one test case will
demonstrate successful energetic service life for a given lifecycle of
vibration exposure. Transition the final product to appropriate users. The
technology developed will benefit the private sector in terms of energetic
concerns for space launch vehicles as well as contractor weapon system
development and evaluation.
1. Environmental Engineering
Considerations And Laboratory Tests, MIL-STD-810G w/Change-1, 15 April, 2014. http://everyspec.com/MIL-STD/MIL-STD-0800-0899/MIL-STD-810G_CHG-1_50560/
2. Hazard Assessment Tests
For Non-Nuclear Munitions, MIL-STD-2105D, 19 April 2011. http://everyspec.com/MIL-STD/MIL-STD-2000-2999/MIL-STD-2105D_34120/
Vibration Testing; Vibration Induced Damage; Energetic Wear, Failure, and
Decomposition; Miner Palmgren Hypothesis; Energetic Material Properties;
** TOPIC NOTICE **
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