Innovative Methodologies for Developing Large Mass High Velocity Projectiles

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Hypersonics; Advanced Materials; The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: Develop large-mass projectiles at high velocities for impact testing. DESCRIPTION: High-velocity impact testing supports development of modeling and simulation tools used for ground testing of projectiles and munitions. The ground test approaches now in use include light gas gun projectiles in a multi-stage light gas gun test facility, and explosively formed projectiles used in an arena test facility. These approaches to date will either provide a large mass with lower velocities, or a high velocity with smaller mass. A highly innovative new approach is sought that would vastly exceed current state-of-the-art capabilities (see references), by combining large projectile mass and high velocity in the same test. Performance improvement by an order of magnitude over the capabilities listed in the references is sought. Reliably, repeat-ably and affordably meeting the goal of a large mass and a high velocity with the same method would require an innovative method that is entirely new. PHASE I: Identify and examine one or more large-mass high-velocity projectile concepts that have the potential to work within the desired parameter ranges. Complete a feasibility study, identifying risks and risk mitigations for the concept or concepts under study, and determining whether there is an approach that has the best likelihood of success. Develop a research and development model of the concept in order to support down-select. Provide a methodology for using experimental data to anchor modeling and simulation tools. Incorporate analytical results and test data from the technical literature. PHASE II: Provide a detailed experimental design for a large-mass high-velocity projectile test facility, and demonstrate the concept as a prototype capability. Fabricate a prototype facility and test performance over a range of payload masses and desired velocities. Include comparison against model runs as part of the Phase II effort. Improve the fidelity of the models based on the information gathered in testing. Test results should anchor modeling and simulation tools used to predict performance. Conduct an initial assessment of economic viability, based on test costs and required customer base. PHASE III DUAL USE APPLICATIONS: Transition the large-mass high-velocity modeling capability to an appropriate hydro-code and execute model runs for design and analysis cases of interest to the government. Conduct lethality ground tests for Department of Defense customers. Transition the technology to support of both government agencies and contractor companies. Other applications for the technology may be relevant to mining, digging wells for oil and gas, cutting and forming metal, or weapons systems (e.g. anti-armor weapons). REFERENCES: 1. Campbell, Increased Launching Capabilities at AEDC's Range/Track G, https://apps.dtic.mil/sti/tr/pdf/ADA355806.pdf 2. Helminiak, Sable, Harstad, Gullerud, Hollenshead, and Hertel, Characterizing In-Flight Temperature of Explosively Formed Projectiles in CTH, Procedia Engineering 204 (2017) 178-185. 3. Kerrisk and Meier, Problems Associated with Launching Hypervelocity Projectiles from the Fast Shock Tube, International Journal of Impact Engineering, Volume 14, pp417-426, 1993. 4. Laird and Palazotto, Gouge development during hypervelocity sliding impact, International Journal of Impact Engineering, Volume 30, Issue 2, February 2004, Pages 205-223. 5. Libersky, Randles, Carney, and Dickinson, Recent Improvements in SPH Modeling of Hypervelocity Impact, International Journal of Impact Engineering Volume 20, Issues 6 10, 1997, Pages 525-532. 6. Liu JQ et al, Formation of explosively formed penetrator with fins and its flight characteristics, Defence Technology, Vol. 10, Issue 2, June 2014, pp 119-123 7. Miller, A new design criteria for explosively-formed hypervelocity projectile (EFHP), International Journal of Impact Engineering Volume 10, Issues 1 4, 1990, Pages 403-411 8. Mueller and Fernando, The Dynamics of Project8iles Launched by a Two-State Light-Gas Gun, QUEST Technical Report No. 547, November 1991, https://apps.dtic.mil/sti/tr/pdf/ADA274380.pdf 9. Peng Chen et al, Formation of explosively-formed projectile with tail fins using polygonal charges, Latin American Journal of Solids and Structures, https://doi.org/10.1590/1679-78257928 10. Piekutowski and Poormon, Meeting the challenges of hypervelocity impact testing at 10 km/s, International Journal of Impact Engineering Volume 180, October 2023, 104665, https://doi.org/10.1016/j.ijimpeng.2023.104665 11. Sobota, Babcock, and Humphrey, Development of a Scramaccelerator Based Hypervelocity Launcher, International Journal of Impact Engineering, Volume 14, pp 695-706, 1993. 12. Test Facility Guide, https://www.arnold.af.mil/Portals/49/documents/AFD-080625-010.pdf?ver=2016-06-16-100801-260 13. Walker, Grosch, and Mullin, A Hypervelocity Fragment Launcher Based on an Inhibited Shaped Charge, International Journal of Impact Engineering, Volume 14, pp763-774, 1993. KEYWORDS: Hypervelocity Projectile; Explosively Formed Projectile; Impact Testing