ONR Advanced Energetic Materials Synthesis and Formulation ...

#SerdpEstcp2018DISTRIBUTION A. Approved for public release: distribution unlimited.

ONR Advanced Energetic Materials Synthesis and Formulation Efforts

Dr. Chad StoltzMr. Matthew BeyardOffice of Naval ResearchCode [email protected]


Overview

2

• Advanced Energetic Materials Program (in relation to ONR)• funding profile, thrust areas, investment strategy, program direction

• Formulation Development Cycle

• Energetic Ingredients• chemical properties, energetic considerations

• Historic “Green” Efforts

• ONR AEM New Directions/relevant programs • Select 6.1 (academia) and 6.2 Navy and Industry

• Summary


Advanced Energetic Materials

3

Reactive Material Fragments

Program Objective: Naval power projection with safe, cost-effective ordnance with precision & adaptable effects

Program Approach: Enhanced performance and safety for weapon systems:

• New energetic materials and energetic material concepts to enhance warhead and propellant performance

• Novel dynamic diagnostics development and implementation – understanding complex energy release

• Atomistic through continuum level predictive solutions –properties prediction, performance, IM requirements composite design, lethality

• Reduce the energetic material sensitivity to initiation by external unplanned stimuli without reducing performance

Program Payoff:• Increase lethality, range, and speed of munitions• Improved safety and reduced vulnerability


ONR S&T Framework

4


ONR Code 35 AEM

5

Advanced Energetic Materials Program• Code 35 – Air and Surface Weapons • DE/CDE, RG, Autonomy, Aerodynamics, Hypersonics….Energetic Materials• Leverage with other ONR codes (352, 30, 33), services (Army, AF), and funding agencies (DTRA, DARPA, DHS, MDA, etc.)• Balance S&T with warfighter needs

Funding Profile:• 6.1 Core ($2.4M) – Academia (mostly)• 6.2 Core ($4.9M) – Navy/DoD Labs, Industry• Non-Core: YIP, DURIP, SBIR, STTR, plus-ups (FY18 - $16M)

Performers: • 6.1: Temple, Washington State, Texas Tech, Stanford, MIT, Hawaii, U of FL, Maryland, Cal Tech, Georgia Tech, Brown, LMU

Munich, Scripps, Purdue, NJIT, U of VA, UCSB, U of Michigan, Cornell U., • 6.2: NSWC IHEODTD, NAWC WD, NSWC DD, NSWC Crane, USNA, NPS, NRL, ARL, various industry (SRI)• SBIR/STTR: NALAS, PSI, RMII, MATSYS, Helicon• YIP: MIT, Duke, Purdue• MURI: 1) Johns Hopkins, Utah, Maryland, NPS, UC Berkeley,

2) Purdue, Stanford, LANL, 3) Stanford, U Toronto, Northeastern, USC


Broad Thrust Areas

6

• Propulsion:

• Higher performance – range and speed

• need to be able to use the energy more efficiently

• need to control energy release better (on/off propulsion?)

• walk the line between kinetic stability and increased energy release rates

• Explosives/Effects

• need to couple energy output to targets more effectively

• Higher energy? Or selectable energy/effects?

• Smaller package, same or greater lethality

• a lot of opportunity

• All of this requires fundamental understanding and combined efforts: new ingredients, new formulations, advanced diagnostics, modeling/simulation

Technology push vs. technology pull (where are the demand signals?)


Investment Strategy

7

Synthesis Quantum Mechanics

Continuum MechanicsDiagnostics

EnergeticMaterials

Work Across Research Domains is Essential for Progress

Key Questions:• At atomistic level

what drives the reaction chemistry?

• At molecular levelwhat stabilizes ignition and growth?

• At composite level• what desensitizes global

reaction?


AEM Program Direction

8

• Molecular Design/Synthesis/Ingredients• High energy density oxidizers/fuels, cage structures (ex. CL-20)• More inclusive of “materials”, i.e. polymers/binders, fuels,

composites, continuous flow • Ingredients/materials amenable to special

applications/manufacturing (RAM, CFR)• Enhanced grain solids loading, additive manufacturing of energetics, etc.

• Detonation, Combustion & Propulsion Diagnostics• Shock physics, detonation science, novel combustion phenomena• Ignition, kinetics/mechanisms, stability/reactivity, formulations/IM• Characterize/push ingredient transitions and feed/validate modeling

• Why are certain ingredients unstable – how do we make them “usable”

• Computational QM & Continuum Modeling• Atomistic à Mesoscale, material properties and behavioral predictions• predict performance/stability, model lethality, understand/improve IM• Drive synthesis, draw from/drive diagnostics, predict effects

6.1 6.2 .Methodology à Targets/scale upPolymer Chem. à FormulationsInterfac. Interact.

Diag. Develop. à Shock/Det. Sci.Combustion à Propulsion

Atomistic Sim. à Mol. PropertiesMultiscale Mod. à Lethality Codes

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Explosive/Propellant Development Cycle

Characterization

ChemicalSynthesis

Scale Up

Formulation ofExplosives

Processing

Formulation of Propellants

Transition to Acquisition

SponsorRequirements

MolecularDesign

Testing/Characterization


• Stable Monopropellants/Oxidizers– High oxygen content

– Thermal stability

– Efficient synthesis pathway

• High density fuels– High hydrogen content

– Efficient synthesis pathway

– Zero-oxygen balance

– Salts and Magic Clusters

• Energetic binder/polymers– High oxygen content

– Selectable mechanical properties

•Advanced Insensitive Mono-propellant Molecules• > Oxygen balance

(Balance to CO/CO2, N2, H2O)• DHf > 0 Kcal/mol• C,H,N,O building elements• Maximum impact/friction/electrostatic/shock and thermal stability (>200 oC) for IM compliance• Density > 1.9 g/cc• M.P. > 150 o C; Thermal stability (>200 oC) • Minimum # synthesis steps

Advanced Energetic Oxidizers• Oxygen content superior to AP (> 2.5 O Balance to CO, N2, H2O)• C,H,N,O building elements• M.P. > 150 o C; Thermal stability (>200 oC) • Minimum # synthesis steps• Density > 1.9 g/cc• Economic or Bulk Starting Materials

•Fuels and binders

Ingredient Properties


Energetic Considerations

11

• Thermodynamics• Heat of Formation (e.g., C + 4H = CH4; DHf = DH(P-R)• Total Reaction Enthalphy (DHR (P-R) < 0; CH4 + O2 = CO2 + 2H2O)• Oxygen Balance

• Kinetics• Reaction Rate (intra- vs. inter- molecular)

• Activation Energy (k = Ze-Ea/RT), where k = rate constant,Z = pre-exponential factor, Ea = activation energy, R = ideal gas constant

• Density• Gas production

• (PV = nRT) (dW = PdV)

• Propellants• Specific Impulse (Isp) is: Impulse produced per weight of propellant burned in a given time

(Isp = F/m = FDt /Dm = K • (Tc/MW)1/2 )• Density impulse is: Isp • propellant bulk density (ρ Isp (N-sec/m3 or lbf-sec/in3)• Doubling missile speed ~ quadruples its range (DV = Isp • g • In(mi/mf)

(g = gravitational acceleration (9.80665 m/s2))

• Explosives• Detonation Pressure (PCJ a ρ0

2 • n • MW1/2 • Q1/2 ]• Detonation Velocity [Dv a ρ (n • MW1/2 • Q1/2)1/2]

E

R.C.


Some Historic “Green” Efforts

12

(2001) “Green Energetics at Naval Surface Warfare Center, Indian-Head Division”, Advanced Research Workshop of the Scientific Affairs Division of NATO "Science and Technology Related to Security Impact of Conventional Munitions on the Environment and Population” Porto, Portugal, 30 October 2001 – NSWC IHEODTD, SRI, Aerojet

Discussion Topics: - Biocatalysis - Oxidative Coupling Using Peroxidase- Polymerizations in liquid and supercritical CO2 (Oxetanes, TPE’s)- Nitration of alcohols and amines, liquid and supercritical CO2- Hydrogenolysis reactions of CL-20 precursors, liquid and supercritical CO2

NO2NO2

2,3-Dimethyl-2,3-dinitro-butane (DMDNB)

O

R'R

HO O

R R'

HnLewis Acid

L-CO2(HO-Z-OH)

initiatorO

O

H

HOOH

CH2OH

(

)nO

O2NOONO2

CH2ONO2

)nN2O5 or HNO3

O

H

(

TAIW TAMF, 94%

N N

N N

N NCH2C6H5C6H5H2C

COCH3

COCH3

H3COC

H3COCN N

N N

N NHOHC

COCH3

COCH3

H3COC

H3COCscCO2, Pd/C, H2, HCO2H

40 deg C, 1700 psi, 5h

CD CDN


Some Historic “Green” Efforts - 2

(2005) Green Energetic Materials S&T, Past, Present, and Future”, Partners in Environmental Technology Technical Symposium & Workshop, Washington, DC, 01 December 2005 – NSWC IHEODTD

Additional Topics: - High Nitrogen Compounds- Novel Oxidizers (ADN, ADNA, ADNDNE, Ionic Liquids/AFRL)- Biocatalytic Syntheses of Energetic Ingredients- Lead Azide and Styphnate Primer Replacements (PacSci, LANL, ARDEC)- Reclaimation/Recovery (Reclaimed HMX, LANL Resource Recovery and Reuse “R3”)- Stockpile Conversion (Explosive D/Picric Acid à TATB, HTX for perforating oil wells)- Perchlorate Contaminated Groundwater Bioremediation

N

N

N

N

HN

N

N

N

N

NH

NN

N

N

NN

N

NAZO-TATTz


6.1 ONR AEM New Directions

14

• ONR AEM 6.1, 6.2 Core Program Re-compete

• Solicited many new start efforts for FY19 and beyond:

• Novel Diagnostics (Combustion/Shock/Detonation)• Modeling/Simulation (Atomistic à Multiscale/Continuum)

• 6.1 Materials:- Synthetic Methodology- New Material Directions- Advanced Manufacturing: RAM, Continuous Flow Technology

Feed 6.2 efforts in DoD Labs: Scale up, Explosive/Propellant Formulations


Cornell University / Song Lin

15

Picture

Schedule/MilestonesMonths 1-12: Nitration of alkenes and arenes (Aim 1)

Months 12-24: Nitration of secondary amines (Aim 2)

Months 1-18: Chlorination of imines for DCG synthesis (Aim 3)

Objective/DescriptionWe will aim to develop electrochemical nitration ofalkenes, arenes, and amines using NaNO2 as the nitrosource and electricity as the redox equivalent andprimary energy input.

Payoffs/Key TechnologiesWe anticipate that our design principle will lead tosafer, streamlined, and more sustainable syntheses ofenergetic compounds and offer a new avenue for thediscovery of novel materials.

Funding–Current year plus out years

POC’s–Dr. Chad Stoltz, ONR–Isabella DiFranzo, Cornell University

Safer, more practical and sustainable technologies

R RR

NH

R

NO2NO2

“privileged” and new energetic materials

readily available starting materials

Electro-chemistry

Cat-alysis

NO2R

R NO2

NO2 RN

R

NO2

+ NaNO2


Purdue University / Davin Piercey

16

Picture

Schedule/MilestonesNotification of Award: 10/18/2016

Once in place:• Initial main focus will be on the energetic 1,2,4-

triazines thrust with simultaneous experiments in the other thrusts as minor focus.

• Current plan is to spend ~1 year on each thrust. This is subject to as-determined success, and

more/less time may be spend on individual thrusts as warranted by current successes.

Objective/DescriptionEnabling energetics work with 3 major thrusts:• Energetic 1,2,4-triazines: 1) IMs with amino-nitro interactions 2)

annulated to 1,2,3,4-tetrazine-1,3-dioxides.• Nitrene insertions for prep of high-performing energetics and oxidizers• Hypofluorous acid and potassium superoxide for direct oxidation of

amines to nitro groups

Payoffs/Key Technologies• New route of tetrazine dioxide heterocycle synthesis opening up new

very high performing energetics• Insensitive energetics from simple precursors• Newly-available 6 membered heterocyclic backbones for new energetics• Simultaneous oxidation of amine and heterocycle to nitroheterocycle

oxides: scalable syntheses of high-performing energetics.

Funding–$186,370.16 (yr1), $158,082.95 (yr2), $159,836.66 (yr3)

POC’s–Navy: Chad Stolz–Institution Financial POC: Suzanne Payne, [email protected]


Scripps Research/ Phil Baran

17

Targets

Schedule/Milestones– Last Proposal Peer Review

Date: August 2018

– First five targets to be delivered

by 2nd Quarter of 2019

– Additional target designs based

on experimental measurements

Objective/Description

Payoffs/Key Technologies

Funding–Current year (Direct Costs): $63,973

–Out years (Direct Costs): $191,919

POC’s–Navy – Dr. Chad Stoltz

–Scripps Research – Tommy R. Rice

N N

NN

O

O

NN

NN

H

H H

H

N

NNN N

N

NH

HN

NH

NH

NNN

Strain as a design principle for air-

breather materials

Identification of safer, more powerful,

“spring loaded” air-breather materials


UC Santa Barbara / Javier Read de Alaniz

18

Design of Stimuli Controlled Crosslinking

Schedule/MilestonesFY19: Design and develop rapid curing

polymer/catalyst blendFY20: Study the properties of new polymer

binder systemFY21: 3D printing of polymer binder in

desired form

Objective/Description• Develop a photo- or thermal-based

process for stimuli controlled curing• Develop new polymer binders to use in

additive manufacturingPayoffs/Key Technologies

• Development of a process for 3D printing solid rocket propellant

Funding– 2019 $150K– 2020 $150K– 2021 $150K

POC’s– Javier Read de Alaniz, [email protected]– Financial: Rebecca Eggeman,

[email protected]

3D printing compatible

Heat or Light

New polymer binders


University of VA / Guarav Giri

19

Picture

Schedule/Milestones

• Yr 1: Forming EM polymorphs using solution shearing

– Milestone: EM polymorph isolation using processing parameter control

• Yr 1: Studying stability of EM polymorphs to solvents and humidity

– Milestone: Stable EM for field usage• Yr 2: Creation of large scale EM polymorph

samples for testing– Milestone: Testable sample creation

• Yr 2: Studying density and performance of EM

Objective/Description• Flow coating Technique to control EM

polymorphism and morphology• Study novel polymorph and morphology

stability and densityPayoffs/Key Technologies

• Novel polymorphs with increased stabilityand efficacy

• Creation of macrostructures using thin filmsas base layers

Funding–Yr 1: $48,982 ($33,357 direct)–Yr 2: $50,197 ($34,216 direct)

POC’s–Dr. Chad Stoltz–Dr. Zbigniew Dreger–Urmila Bajaj, Director of Post-Award, UVA

Packing Control

Morphology Control


University of Munich (LMU) / Thomas M. Klapötke

20

Funding–USD 428,950 (2019 – 2021)

POC’s–Navy–Institution Financial POC

MR setup, NQ, PETN, FOX-7, HMX4 conv. explosives, 25 g scaleNew polynitro explosives, nitramines, polyazides, TNT, tetryl8 new explosives, 10 – 25 g scaleUpscaling 100 g (conv.) 25 g (new)4 conv. explosives, 100 g scale

Schedular / Milestones

Safe on demand preparation of currentlyused and new explosives by flow techniques.Upscaling with improved yields and purity.Multi-purpose flow reactors for explosives.

Safe production at lower costs.Higher mobility and flexibility.Wide applicability of a green technology.

Objective / Description

Payoffs / Key technologies

2019

2020

2021


Continuous Flow Technology – NSWC IHEODTD

21

Advantages Over Batch Processes § Superior mixing, heat transfer due to high SA§ Smaller reaction volumes§ Reduced solvent use; less waste generated§ Higher energy efficiency, Smaller footprint§ More flexible platform for scale-up

Corning HEART cell fluidic module

Possible Benefits of Continuous Flow§ Ability to increase reaction rates§ Yield improvement of desired products§ Selectivity for desired product over by-products§ Reduce/avoid build-up of reactive intermediates§ Safer, more environmentally friendly processes§ Finer control over physical properties

Corning G1 Advanced Flow Reactor

Challenges§ Chemical syntheses must be scalable and cost-

effective to transition to higher TRL’s. § Need for capability to rapidly synthesize critical

obsolescent ingredients to spec so currently fielded systems remain supported.

Technical Approach

§ Develop, compare, and contrast continuous flow capabilities for chemical process development.

§ Demonstrate scalability in continuous flow systems and ability to intensify chemical processes to reduce cost and improve product quality.


Optimizing the Synthesis of PTX – N.G.

22

• PTX is a promising new energetic material due to the favorable combination of attractive energetic properties and excellent safety properties

• PTX was developed initially by Dalinger et al. in Russia (Russ. Chem. Bull. 2010, 59, 1631-1638)– seven step synthesis, 10% overall yield

• The route was improved by Chavez et al. at LANL (J. Mater. Chem. A 2015, 3, 17963-17965)– three step synthesis, 30% overall yield

• ONR has contracted Northrop Grumman Innovation Systems (formerly Orbital ATK) to improve the synthesis further for scale up and provide sufficient material for evaluation by Navy researchers

• Planned studies are targeting significant reductions in solvent and reagent quantities, increased yields (yielding smaller waste streams), and switching to less hazardous (and often more environmentally friendly) solvents and reagents

Chavez Route

density = 1.95 g/ccHf = 88.4 kcal/mol (calc)OBAL = 0.0

DNP ADNPNP


Optimizing the Synthesis of ADNP – N.G.

23

• Penultimate precursor to PTX• Significant reductions in solvents achieved and further planned

• Economical process developed (solvent trituration) to reclaim unreacted starting material (DNP)• Will reduce required quantities of DNP starting material by 10%

DNP

ADNP


Summary

24

ONR AEM Program Approach focuses on Enhanced performance and safety for weapon systems by development of New energetic materials and concepts to enhance warhead and propellant performance

Thrust Areas include:

• Novel dynamic diagnostics development and implementation • Development of atomistic through continuum level predictive solutions • Molecular Design/Synthesis/Ingredients

- High energy density oxidizers/fuels, cage structures (ex. CL-20) – high performance!- Novel Synthetic Methodology- More inclusive of “materials”, i.e. polymers/binders, fuels, composites- Advanced Manufacturing: Continuous Flow, RAM (CAR), additive manufacturing of energetics

• IM: Reduce energetic material sensitivity to initiation by external unplanned stimuli without reducing performance

• 6.2/6.3 (non-Distro A) topics/programs – happy to discuss as appropriate

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