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TECHNICAL REPORT ARLCD-TR-84031

COMPARISON OF PAPER MOLDING AND SLURRY PROCESSES FOR MANUFACTURE OF

60-MM M204 AND 81-MM M205 PROPELLING CHARGE CONTAINERS

ANTHONY F. TASCHLER HOWARD SHIMM

ANDREW ZAYCER

FEBRUARY 1985

U.S. ARMY ARMAMENT RESEARCH AND DEVELOPMENT CENTER LARGE CALIBER WEAPON SYSTEMS LABORATORY

DOVER, NEW JERSEY

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED.

The views, opinions, and/or findings contained in this report are those of the author(s) and should not be construed as an official Department of the Army position, policy, or decision, unless so designated by other documentation.

The citation in this report of the names of commercial firms or commercially available products or services does not constitute official endorsement by or approval of the U.S. Government.

Destroy this report when no longer needed. Do not return to the originator.

UNCLASSIFIED SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)

REPORT DOCUMENTATION PAGE 1. REPORT NUMBER

Technical Report ARLCD-TR-84031

2. GOVT ACCESSION NO

4. TITLE (and Subtitle)

COMPARISON OF PAPER MOLDING AND SLURRY PROCESSES FOR MANUFACTURE OF 60-mm M204 AND 81-mm M205 PROPELLING CHARGE CONTAINERS

READ INSTRUCTIONS BEFORE COMPLETING FORM

3. RECIPIENT'S CATALOG NUMBER

5. TYPE OF REPORT & PERIOD COVERED

October T98.Warmprv 1 Q84 6. PERFORMING ORG. REPORT NUMBER

7. AUTHORfsJ

Anthony F. Taschler Howard Shimm Andrew Zaycer

8. CONTRACT OR GRANT NUMBERfs.)

9. PERFORMING ORGANIZATION NAME AND ADDRESS

ARDC, LCWSL Applied Sciences Div (SMCAR-LCA-G) Dover, NJ 07801-5001

10. PROGRAM ELEMENT, PROJECT, TASK AREA ft WORK UNIT NUMBERS

11. CONTROLLING OFFICE NAME AND ADDRESS

ARDC, TSD STINFO Div (SMCAR-TSS) Dover. NJ 07801-5001

M. MONITORING AGENCY NAME ft ADDRESSf//d(«oren< from Controlling Oltlce)

12. REPORT DATE

February 1985 13. NUMBER OF PAGES

22 15. SECURITY CLASS, (of this report)

Unclassified

15«. DECLASSIFI CATION/DOWN GRADING SCHEDULE

16. DISTRIBUTION STATEMENT (W (Ms Report)

Approved for public release; distribution unlimited.

17. DISTRIBUTION STATEMENT (of the abstract entered In Block 20, If different from Report)

18. SUPPLEMENTARY NOTES

19. KEY WORDS (Continue on reverse side If necessary and Identify by block number)

Nitrocellulose Paper molding process Residue test M204 propelling charge M205 propelling charge Ballistics Velocity

Slurry process 60-mm mortar 81-ram mortar Pressure

Puddle test Transportation rough handling test

20. ABSTRACT (Xtanttmie ea nvram »£t*» ff naxvaaaiy aad Identify by block number)

A ballistic test program was conducted and the results were statistically evaluated to compare nitrocellulose mortar increment containers made by both the paper molding process and the slurry process. These containers were for the M204 propelling charges for the 60-mm mortars and for the M205 propelling charges for the 81-mm mortars.

DD Z FORM AN 73 1473 EDITION OF » NOV 65 IS OBSOLETE UNCLASSIFIED SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)

SECURITY CLASSIFICATION OF THIS PAGEfWhan Data Entetad)

SECURITY CLASSIFICATION OF THIS PAGEOfTion Da(a Entsrod;

CONTENTS

Page

Introduction I

Discussion 1

Statistical Evaluation 2

Conclusions 3

Reconunendations ^

References 5

Distribution List I7

INTRODDCTION

A new two-step, hot forming, progressive molding process was developed for the 60-mm M204 and 81-nim M205 propelling charge increment containers. The pro- cess which used nitrocellulose paper was manufactured in accordance with specifi- cation MIL-P-70475 and eliminated the use of organic solvent.^ A total of 4,000 60-ram M204 and 2,650 81-mm M205 increment container assemblies were manufactured and met the contract requirements (ref 1). The present container assemblies are manufactured by a slurry process.

A test program was developed to compare paper molded 60-mm M204 and 81-mm M205 propelling charge increment containers manufactured by INNOVA, Inc. with increment container assemblies made by the ARMTEC slurry process with respect to ballistics.

2 The ballistic test plan was designed in accordance with specification MIL-

C-48868 for the M204 propelling charge and specification MIL-C-48882 for the M205 propelling charge.

The test program used samples from the INNOVA paper process and the ARMTEC slurry process and included such tests as:

1. Hot, +1450F; ambient, +70oF; cold, -50oF

2. Residue

3. Puddle at +70oF

4. 10-day humidity

5. Transportation rough handling at +1450F and -40oF

DISCUSSION

The ballistic tests were carried out at Camp Edward, Massachusetts. The test program specified the number of increment containers made by the paper and slurry processes and the number of rounds to be loaded for the residue, puddle, and temperature extremes tests. Velocities and pressures were obtained at +1450F, +70oF, and -40oF; also, at +70oF for the puddle test.

The old paper process used organic solvent in the preform operation of the process.

2 Test Program Requests LCA-G-2849 and LCA-G-2850.

STATISTICAL EVALUATION

It was decided to test the hypothesis that If two populations (velocities of containers made by the slurry process and by the paper process) have normal dis- tributions with the same means and the same variances, then the statistics have a T-dlstributlon (ref 3, page 117). This hypothesis was tested for the M205 Incre- ment container at charges 2 through 4 at temperatures of -40, +70, and +1450F. The hypothesis was accepted since the mean velocities and variances of the paper containers are the same as the mean velocities of the slurry containers; for example, charges 2 through 4 at temperature +70oF.

Mean velocities

Charges

2

3

4

Paper (ft/sec)

605.0

754.3

.879.9

Slurry (ft/sec)

602.5

752.0

883.2

Charges 2 through 4 at -40 and +145°F are described In table I. It can be concluded that the mean velocities using the paper containers were the same as the mean velocities using the slurry containers for the charges 2 through 4. The same populations (from table 1) show that the mean velocities were the same for the charges 2 through 4 and the puddle test. It was also noted that there was no significant difference in the pressure.

The same hypothesis was also tested for the M204 container but the hypoth- esis was not accepted since the means were different; for example, charges 2 through 4 at +70oF.

Mean velocities

Paper (ft/sec)

543.0

667.4

764.0

Slurry (ft/sec)

531.0

656.1

756.7

This difference may be due to the ignition cartridge used (Lot MA-80K002- 003) which was accepted on waiver because of a high standard deviation. The

ignition cartridge lot used during the ballistic testing had a history of gener- ating high standard deviations. In the past, the substitution of a different ignition cartridge lot has been shown to bring the standard deviations and means down to acceptable levels. It is felt that if a new lot of Ignition cartridges is used, the mean velocities and standard deviations will be the same for both the M204 paper and slurry containers. This change would make the paper con- tainers equivalent to the slurry containers.

The raw data (velocity in ft/sec) is plotted in figures 1 and 2. The data are for the velocity of charges 2, 3, and 4 at temperatures -40, +70, and +1450F; and charge 4 for the puddle test. A graphical comparison of the data is made by plotting all the Individual data points (represented by X's) and the mean of each set of data points represented by lines. The graph is an ideal method for visu- alizing differences in the data. The data for container assemblies made by the paper process appear to have about the same dispersion as the data of the con- tainer assemblies made by the slurry process for both the 60-mm and the 8l-mm. The graph is another method for showing that the container assemblies made by the paper process are similar to the container assemblies made by the slurry process.

The 30-second puddle test did not significantly affect the velocity of the Increment containers made by either process.

Results of the residue test—conducted in accordance with MIL-C-4882 and MIL-C-48868—are contained in tables 2 and 3. Included in the tables are the number of flaming debris and scorchers for 25 rounds of each charge. There were no hangups; no rounds exhibited secondary flame at any charge; and no flaming debris was observed at charge 4. The tube was dry-swabbed after each 25-round series and there was no evidence of residue. The tube was turned over after each 25-round series and there was no evidence of residue.

The velocity results of rounds tested after transportation rough handling, listed in tables 4 and 5, were not significantly affected by the hot and cold cycling of the test. No propelling charges were broken and all rounds functioned as required. The transportation rough handling test also shows that the paper- molded Increment containers are ballistically equivalent to the slurry-processed increment containers.

CONCLUSIONS

1. The results of the 10-day temperature/humidity tests (table 6) showed that the paper-molded Increment containers and the slurry-molded containers were not significantly affected by the tests (30-sec puddle test, residue test, trans- portation rough handling test, 10-day humidity test, and the ballistic tempera- ture extremes test).

2. The paper-molded containers and the slurry-molded containers are ballis- tically equivalent.

3. The paper-moldsd process can be used for the M204 and M205 container assemblies.

RECOMMENDATIONS

It Is recommended that the drawings and specifications be issued for the 60- mm M204 and 81-mm M205 propelling charge increment containers to include the paper process as a manufacturing option in addition to the slurry process.

The paper process can be used as an alternate process for the manufacture of the 60-mm M204 and 81-ram M205 propelling charge increment containers.

REFKRENCES

1. Michael D. Saxon, "Prototype Production Tooling for Paper Molding 60mra, M204 and 81mm, M205 Propellant Charge Increment Containers," Contractor Report, 1NN0VA, Inc., 5170 126th Avenue North, Clearwater, FL 33520, February 22, 1984.

2. Wilfred Dlxon and Frank J. Massey, Jr., Introduction to Statistical Analysis, third edition, McGraw-Hill Book Co., New York, 1969.

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Table 2. Results of residue test of M205 propelling charge

Type of Flaming Charge container debris Scorchers

1 paper 1 6

1 slurry 3 4

2 paper 1 0

2 slurry 0 2

3 paper 0 0

1 paper 1 6

4 paper 0 0

A slurry 0 0

1 paper 0 2

2 paper 0 1

Time in min/sec required to fire 25 rds

5 min.

5 rain. 30 sec.

2 min. 40 sec.

2 min. 30 sec.

2 min.

1 min. 10 sec.

3 min. 10 sec.

2 min. 35 sec.

1 rain. 50 sec .

1 rain. 55 sec.

NOTES:

a. Conducted in accordance with para. 4.5.5. of MIL-C-48882.

b. Reference TPR-2850

Table 3. Results of residue test of M204 propelling charge

Type of Flaming Charge container debris Scorchers

1 paper 3 0

1 slurry 0 5

2 paper 1 1

2 slurry 2 0

3 paper 2 0

1 paper 0 0

4 paper 0 0

4 slurry 0 1

1 paper 0 5

2 paper 0 3

Time in min/sec required to fire 25 rds

3 min.

2 min. 30 sec.

1 min. 10 sec.

1 min. 30 sec.

1 rain. 30 sec.

1 min. 20 sec.

2 rain.

2 rain.

1 rain. 10 sec.

2 min.*

* Tenth round did not fire (misfire) because of a bad ignition cartridge. A new ignition cartridge was added and the round fired.

NOTES:

a. Conducted in accordance with para. 4.5.5. of MIL-C-48868

b. Reference TPR-2849

Table 4. Results of transportation rough handling test of M204 propelling charge

Paper Slurry Velocity (ft/sec) Velocity (ft/sec)

Temperature (+1450F)

787 772 794 779 797 . 781 792 766 795 795 795 781 804 764 791 784

x 794 x 778

o 4.96 a 10.14

Temperature (-40oF)

785 772 789 775 776 velocity lost 795 782 793 778 779 768 792 773 784 772

787 x 774

6.82 o 4.37

NOTKS:

a. Conducted in accordance with para. 4.5.7 of MIL-C-48868

b. No propelling charges were broken open; all rounds functioned (32 rounds were fired).

10

Table 5. Results of transportation rough handling test of M205 propelling charge

Paper Slurry Velocity (ft/sec) Velocity (ft/sec)

Temperature (+1450F)

888 881 887 882 892 890

x 889 x 884

o 2.65 a 4.93

Temperature (-40oF)

888 883 887 886 882 878

886 x 882

3.32 a 4.04

NOTES:

a. Conducted in accordance with para 4.5.7 of MIL-C-48882.

b. No propelling charges were broken open and all rounds functioned (12 rounds were fired).

11

Table 6. 10-day humidity test of 60-mm M204 and 81-min M205 increment containers at charge 4

NOTES:

x = mean velocities

a = standard deviations

6( J-mm M2 04

Veloc ity (ft :/sec) Paper Slurry

756 737

6.35 11.20

81 -ram M20! >

Vel( 3Ci ty (ft/sec) Paper Slurry

890 880

2.42 2.23

12

910

Charge 4 Puddle Test (°F) (»F)

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Figure 1. Data points of velocity (ft/sec) for charge 4 of M205 container of the 81-mm propelling charge

13

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14

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Figure 2. Data points of velocity (ft/sec) for M204 container of the 60-mm propelling charge

15

650 ^

645

650

-^w Charge 2 Charge 3

(0F) +70 +145 TfP -40 +70 ^145

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Figure 2. (cont)

16

DISTRIBUTION LIST

Commander Armament Research and Development Center U.S. Army Armament, Munitions and Chemical Command ATTN: SMCAR-TSS (5)

SMCAR-LCA-G (10) SMCAR-LCM-E (2) SMCAR-LCU-S (2)

Dover, NJ 07801-5001

Commander U.S. Army Armament, Munitions and Chemical Command ATTN: AMSMC-GCL(D)

AMSMC-QAT-A(D) (2) Dover, NJ 07801-5001

Administrator Defense Technical Information Center ATTN: Accessions Division (12) Cameron Station Alexandria, VA 22314

Director U.S. Army Materiel Systems Analysis Activity ATTN: DRXSY-MP Aberdeen Proving Ground, MD 21005-5066

Commander/Dlrector Chemical Research and Development Center U.S. Army Armament, Munitions and Chemical Command ATTN: SMCCR-SPS-I

SMCCR-RSP-A APG, Edgewood Area, MD 21010-5423

Director Ballistic Research Laboratory ATTN: AMXBR-OD-ST Aberdeen Proving Ground, MD 21005-5066

Chief Benet Weapons Laboratory, LCWSL Armament Research and Development Center U.S. Army Armament, Munitions and Chemical Command ATTN: SMCAR-LCB-TL Watervllet, NY 12189-5000

Commander U.S. Army Armament, Munitions and Chemical Command ATTN: AMSMC-LEP-L Rock Island, IL 61299-6000

17

Director U.S. Army TRADOC Systems Analysis Activity ATTN: ATAA-SL White Sands Missile Range, NM 88002

Commander U.S. Army Production Base Modernization Agency ATTN: AMSMC-PBM-LT(D) Dover, NJ 07801-5001

Anthony F. Taschler 22 Notch Park Road Little Falls, NJ 07424

18