Gun Barrel Coatings - Explosive Bonding

U.S. Army Research, Development and Engineering Command
Gun Barrel Coatings - Explosive Bonding
POC: Frank Campo / Mark Miller
Phone: DSN 374-4770/4177
Frank.Campo@us.army.mil
Mark.Miller9@us.army.mil
RDEC-WSEC-BENET
Date 2/10/2011
ASETSDefense 2011 Workshop
Sustainable Surface Engineering
for Aerospace & Defense
21st Century Weapons Technology
Cannon Life Extension Using Explosive Bonding
Explosive Bonding Ta-10W Overview
PROBLEM:
•
Current Chrome Plating Does Not Provide Adequate Bore Protection
¾ Melting Temperature is Too Low 1850°C
¾ Bio Hazards of Hexavalent Chromium
¾ Gun Tube Life is Too Low – Propellants Drive Service Life
SOLUTION:
•
Explosively Bond a Thick Wall Ta-10W Alloy Liner to Gun Bores
¾ Much Higher Melting Point >3000°C
¾ Ta-10W Liner Provides Robustness
¾ Green Process
¾ Asymmetric Advantage to War Fighters
PROGRESS TO DATE:
•
Medium Caliber Test Bed at YPG 2010
¾ Bonding Adherence Proven
¾ Rifling Technology Developed and Proven !
¾ Test Firing Completed-Test Results Excellent !
¾ Medium Caliber Rapid Firing Testing – Completed !
¾ Exceeded 3 Times the Life a Chrome Barrel…and still Firing Accurately!
Distribution limited to US Government Agencies and their contractors due to Critical technology, Jan, 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension
Using Explosive Bonding
ARDEC’s
W e Ne e d
m-Free
u
i
m
o
r
h
C
!
Coatings
Got You
Both Covered!
Environmental
Weapons and
Green Technology Software Engineering
Community
Center ARDEC-Benet
We Need
Higher M
elti
Tempera ng
ture
Coating
s!
Propellant, Higher
Velocity Ammo
Community
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Project Team
Key Performers
Mr. Frank Campo
Mr. Mark Miller
Mr. Edward Troiano
Dr. Joseph Walden
Mr. Michael Audino
Dr. Sam Sopok
Mr. Arthur Aeberli
Mr. Michael Ellis
Mr. Gary Fleming
Mr. Anthony Cortese
Dr. Ernest Baker
Mr. Mark Witherell
Dr. William de Rosset
Dr. Jonathan Montgomery
Mr. Victor Champagne
Mr. Mark Moore
Mr. Don Butler
Dr. Keith Legg
Organization
U.S. Army Benet Laboratories
U.S. Army Benet Laboratories
U.S. Army Benet Laboratories
U.S. Army Benet Laboratories
U.S. Army Benet Laboratories
U.S. Army Benet Laboratories
U.S. Army Medium Cal Weapons
U.S. Army Medium Cal Ammo
U.S. Army Medium Cal Ammo
U.S. Army Medium Cal Ammo
U.S. Army ARDEC
U.S. Army Benet Laboratories
U.S. Army Research Laboratory
U.S. Army Research Laboratory
U.S. Army Research Laboratory
ARES Inc.
High Energy Metals, Inc.
Rowan Technology Group
Function
Program Manager
PI Material Science
PI Material Science
Technical Advisor
Technical Adviser
Technical Adviser
APO ARDEC
Technical Adviser
Technical Adviser
Technical Adviser
Explosive Modeling
Thermal Modeling
Explosive Analysis
Material Science
Forensics & Analysis
Manufacturing
Cladding Technology
Cost Data Collection
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Technical Objective
•The objective is to develop a production capable process to eliminate
chromium plating* in the production of Large Caliber gun barrels and Weapon
Systems.
• To develop an environmentally acceptable method for depositing wear and
erosion resistant refractory metal materials onto the gun bore surface.
• This 21st Century innovative technology enables weapon systems to fire
higher lethality ammunition and significantly extends the life of a weapon
system/gun barrel.
•.
*As per the under secretary of defense memorandum
Minimizing the Use of Hexavalent Chromium in new weapon systems dated 08 April, 2009
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Root Problem: Chrome Plated Barrel Wear and Erosion
Cannon Life Extension Using Explosive Bonding
Root Cause Problem: Chrome Plated Barrel Wear and Erosion
Fatigue Crack
Growth Rate
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
6
Fracture surface from
120 mm cannon
after fatigue test
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
What’s all this Tantalum-Tungsten Stuff?
Melting Point 1857 °C
Melting Point 3422 °C
Material Selection Goals:
Melting Point 3017 °C
Tungsten
1. Increased surface hardness for improved wear resistance
2Reduced chemical reactivity including hydrogen embrittlement
3. Increased corrosion resistance
4.Enhanced machinability to
accommodate rifling
5. Reduce interface intermetallics
Melting Point 1495 °C
Molybdenum
Tantalum
Melting Point 2623 °C
Stellite
Cobalt
Co is used in
fabricating
high-strength,
high-temperature
steel alloys.
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Technical Approach
The Science of Explosive Bonding
Detonation Products
Collision Angle, α
α
Final Donor
Tube Dia.
Detonation
Velocity, Vd
Initial Donor
Tube Dia.
Donor Tube
Gun Barrel Substrate
Standoff
Plasma Jet
Low Detonation Velocity
Explosive Formulation
Bond Interface
Plasma Jet Scrubs Surface in
Advance of Donor Tube
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
8
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Explosive Bonding Process
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
Explosive Bonding Process
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
Honing & Rifling Process
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
Cannon Life Extension Using Explosive Bonding
Relative Hot Hardness Gun Steel and Thick Wall Liners
80
Relative Hardness (H500g)
70
60
50
40
30
1006, Ta-10W
1007, Ta-5W-2Mo
1008, Stellite 25
1009, Ta-10W
A 723
20
10
0
0
200
400
600
800
1000
Temperature, oC
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
12
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Gun Steel to Ta-10W Bond Line
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Overview of Prototype Work
Prototype Tube Material:
De-Milled M242 tube
Red River Army Depot
36” Truncated M242 25mm Barrel
Section of 18” Truncated Barrel
Ta-10W Donor Tube “Liner”
Sectioned 18” Truncated Barrel
Clad with Ta-10W
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Results from a Design of Experiments for a Ta-10W Rifled Barrel
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Six Sigma Analysis :
=
¾Material Science
¾FEM Modeling
¾Six Sigma, DOE
¾Tribology and Lubrication
¾Fracture and Fatigue Testing
¾Autofrettage Stresses
Rifling
Success !
Gen II Rifling
First Prototype Rifled Ta-10M242 25mm Barrel
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
16
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
First Full-length Rifled Explosively Bonded
Ta-10W Lined M242 25mm Bushmaster Barrel
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
Cannon Life Extension Using Explosive Bonding
TESTING / ACCOMPLISHMENTS
M242 SN 1 Ta-10W Liner
Mann Barrel
Configuration
18
25mm M793
TP-T Round
SN1 Rounds
24 & 26 Barrel Shots
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
TESTING / ACCOMPLISHMENTS
SN1 Ta-10W Mann Barrel
Rifling Before Firing
SN1 Ta-10WMann Barrel Rifling
After Firing 24 Shots with M793 TP-T Rds
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
19
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Firing Tests, YUMA, June 2010
Chromium Plated M242 25mm Bushmaster Barrel vs.
Explosively Bonded Ta-10W M242 Barrel
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
20
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
YPG Testing Status
To date 7 M242 Ta-10W lined tubes have
been fabricated912 Endurance A/B cycle rounds fired
through the barrel SN4
9The liner inspected between inspected
between each endurance cycle.
9The endurance cycle fired bursts at AutoGun high rate mode, 200 rounds per /min
separated with 20 minute cool-down
9Testing Burst duration chosen for best
match to worst case battlefield scenario,
this was also the worst case thermal profile
9Five man Gunnery crew on hand to
support gun/ammo loading
¾Estimated 25,000 equivalent rounds to date
fired through SN4 liner.
9 STILL FIRING ACCURATELY !
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
21
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
The Results of 1 A/B Cycle Testing
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
YPG HARD STAND
GUNPOINT-20
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Distribution limited to DoD only due to Critical technology, July 2010
Cannon Life Extension Using Explosive Bonding
Cycle A/B Endurance Testing Results YPG Tube Rifling
4
Tube SN
Ta-10W
No loss in 8
n after
Dispersio les
A/B Cyc
Chrome Plated Tube , Condemned , 4 A/B Cycles Explosively Bonded Ta‐10W, 8 A/B Cycles
Virtually No
Erosion After 8
A/B Cycles
23Chrome Land Chipped at 1 A/B Cycle
23
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
YPG Endurance Testing Results Chamber and Forcing Cone
Chrome Rifling- Eroded Chamber Worn Below
Tube ID of Gun Steel
Over 0.700 inch (Condemned)
24
Ta-10W- after 12 A/B Endurance Cycles
Less then 0.180 inch Erosion
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
YPG Final Cycle A/B Endurance Test Results Tube Rifling
Explosively Bonded Ta‐10W Liner 12 A/B Cycles Virtually No
Land Erosion
After 12 A/B
Cycles
Origin of Rifling at 12 A/B Cycles
25
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
360°3D LASER SCAN OF TUBE BORES
CHROME
PLATED Ta‐10W
BONDED
Virtually No Erosion
On ID Of Gun Steel
WORN REGION
¾Ta-10W Origin of Rifling Nearly Completely Intact
BELOW BORE ID
STEEL SURFACE
After 12 Endurance Cycles Using Hi Rate Bursts
Fired at 200 Rounds per Min
¾Chrome Origin of Rifling Completely Eroded
Below Base Metal
LTC Scans Provided by:
David LE Yuma Proving Grounds
¾Tube Condemned After 3675 rounds
Hi Rate Bursts Fired at 200 Rounds per Min
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
26
26
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
RDECOM / ARDEC / Benet
Significant Accomplishments
First to Achieve
• Explosively Bonded Ta-10W 25mm Tube
• Rifled M242 Bushmaster Ta-10W 25mm Barrel
• Firing of Explosively Bonded and Rifled Ta-10W M242 25mm Bushmaster Barrel
• Explosively Bonded Powder Ta-10W Metallurgy 25mm Barrel
•Test Fire a Ta-10W M242 Bushmaster Barrel and Exceed Three Times The Chrome Barrels Life
AWARDS
•2009 Defense Manufacturing Award For Ta-10W Lined Gun Barrel Manufacturing Technology
•2010 SERDP Project of The Year Award for Eliminating Chromium in Medium Caliber Gun Barrels
•2010 Army Research and Development Achievement Award EB and Machining Technology
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
28
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.
Cannon Life Extension Using Explosive Bonding
Questions?
POC: Frank Campo / Mark Miller
Phone: 518-266-4770/4177
Frank.Campo@us.army.mil
Mark.Miller9@us.army.mil
ARDEC-WSEC-BENET LABS
Distribution limited to US Government Agencies and their contractors due to Critical technology, January 2011
29
TECHNOLOGY DRIVEN. WARFIGHTER FOCUSED.