Process and Formulation Development of Castable Energetic Formulations using the LabRAM and RAM5 Mixer

摘要

The use of the LabRAM and RAM5 mixers (Resodyn Acoustic Mixers, Butte, Montana, USA) are shownto be efficient and cost-effective development tools for preparation of energetic formulations, particularlycomposite cast-curable solid propellants. Development activity resulting in batch comparisons and scaleupof formulations is described, in the progression of process technology at the pint (half-liter) scale to 5-gallon (approx. 20L) scale. Several technologies are discussed: first, the LabRAM process developmentinvolving both propellant simulants and live formulations, second, mix/cast/cure batch studies that benefitfrom statistical Design of Experiments approaches, and third, the examination of selected properties ofscale using inert propellant formulations prepared in the LabRAM and RAM5 equipment. Key findingsinclude process definition and preparation of typical composite (inert) propellant formulations at the pintscale, scale-up of the formulation to 5gal/50lb batch size, comparison of mix parameters, notablyacceleration, vacuum mix cycles, and resultant temperature of mix. Cost savings as a result of improvedefficiencies of mixing by resonant technology, by mixing in the end-use container (simulated motor case),and elimination of cast procedures or cure oven requirements, are conservatively estimated at much lessthan half the cost of conventional process methods, without consideration of advantages of higherautomation capability, reduced equipment and facility costs, or reduction in hazards by eliminatingrotating machinery in contact with energetic compositions.