Attachment 17_NAVSEAINST_8020.5D.pdf

DEPARTMENT OF THE NAVY

NAVAL SEA SYSTEMS COMMAND

1333 ISAAC HULL AVE SE

WASHINGTON NAVY YARD DC 20376-0001 IN REPLY REFER TO

Distribution Statement C. Distribution authorized to U.S. Government agencies and their contractors due to administrative or operational use (11 March 2019). Other requests for this document shall be referred to Naval Sea Systems Command, NAVSEA 00VW.

NAVSEAINST 8020.5D

Ser N85-1298 1 Apr 2019

NAVSEA INSTRUCTION 8020.5D

From: Commander, Naval Sea Systems Command (SEA 00V)

Subj: QUALIFICATION AND FINAL (TYPE) QUALIFICATION PROCEDURES FOR

NAVY EXPLOSIVES (HIGH EXPLOSIVES, PROPELLANTS, AND

PYROTECHNICS)

Ref: See Enclosure (1)

Encl: (1) References

(2) Definitions

(3) Qualification Procedures for Explosives

(4) Final (Type) Qualification Procedures for Explosives

1. Purpose

a. This instruction establishes policy and provides procedures for approving explosives for Navy use. References (a) through (p) apply to the policy of this instruction and its enclosures.

b. This instruction has been updated to reflect changes in Navy explosive safety policy and changes in Navy and joint service qualification test requirements. The requirement for the Explosive Selection Working Group has been eliminated. This instruction is a complete revision and should be reviewed in its entirety.

2. Cancellation. This instruction supersedes NAVSEAINST 8020.5C of 5 May 2000.

3. Scope and Applicability. This instruction applies to explosives at Navy installations and aboard Navy ships or aircraft, whether designed and built by the Navy or developed by other services, private industry, or foreign sources, and whether intended for operational use, testing, training, or transport. Fleet ballistic missile strategic weapons and nuclear weapons are excluded.

4. Discussion

a. Qualification is the assessment of the explosive material to determine whether it possesses properties that make it safe and suitable for consideration for use in its intended role.

Final (Type) Qualification is granted when the qualified explosive has been assessed as part of the design of a specific munition and is predicted to be safe and suitable for military operational or training use.

NAVSEAINST 8020.5D

1 Apr 2019

b. Naval Sea Systems Command (NAVSEA) is assigned as the Navy Lead Systems Command for energetic materials and insensitive munitions (IM) per reference (a). NAVSEA 00V is assigned as the Technical Authority for explosives safety per reference (b). Lead Systems Command responsibilities include the approval authority for qualification and Final (Type) Qualification of explosives.

c. The term “explosive” is defined in enclosure (2) and specifically includes high explosives, propellants, and pyrotechnics.

d. This instruction is the Navy implementing document for reference (c) and related Standard North Atlantic Treaty Organization Agreements (STANAG). Reference (d) provides relevant test procedures.

5. Policy

a. Per references (a) and (e), IM should be integrated using a systems safety approach, including energetic materials. In selecting an explosive, the program manager should place emphasis on reducing the weapon susceptibility to a violent reaction as a result of unplanned stimuli such as heat, shock, and impact during transportation, storage, and use.

b. Explosives must be qualified per enclosure (3) prior to use in a munitions development or product improvement program. Qualified explosives approved for weapon development are listed in reference (f). Any explosive qualified between revisions of reference (f) will be considered included in reference (f). Approval to use any finalized or developmental explosive not listed in reference (f) must be requested in writing to the Commanding Officer, Naval Ordnance Safety and Security Activity (NOSSA) N85.

c. Explosives that have been in use by another service must be qualified per enclosure (3) prior to use by the Navy. The qualification test plan may be modified as deemed appropriate by NOSSA N85 depending on existing test or performance data.

d. Changes to qualified explosives must be duly recorded by the program manager in the appropriate documents. Slight modifications to the composition of a qualified explosive could have a significant effect on the sensitivity of the material. For previously qualified explosives, any changes in formulation, materials, or processing, or to the process by which the energetic ingredients are made, must be reviewed by NOSSA N85 to determine whether requalification is required and to determine effects on hazard classification, if any. Reviews will be based on sensitivity and other data requested by NOSSA N85 from the explosive formulator.

e. Explosives previously qualified by the Navy and listed in table 3 of reference (f) need only go through the Final (Type) Qualification procedures of enclosure (4).

f. Only Final (Type) Qualified explosives, as defined in enclosure (2), will be employed in munitions and explosive devices introduced for operational or training use. The fact that an explosive has been Final (Type) Qualified for a specific munition does not imply that it is acceptable for other uses. Each new application must be reviewed by NOSSA N85 and approved by NAVSEA 00V.

g. Explosives that are not qualified are only permitted at Navy Research and Development and pilot plant processing facilities for research or development, including synthesis, formulation, processing, and characterization studies up to testing of the next higher assembly.

Testing aboard Navy aircraft and ships is specifically prohibited. Only qualified explosives will be recommended to other government activities, private industry, or allied countries for weapon development.

h. If the need arises to use an unqualified explosive in existing, non-developmental munitions or explosive devices introduced for operational or training use, a written request must be submitted to NOSSA N85 documenting the need to use an unqualified explosive and the special precautions that will be taken to offset the higher hazard associated with its use. If justified, and after NOSSA N85 review, NAVSEA 00V will grant Final (Type) Qualification for use only in the particular application. The explosive will retain its unqualified status.

i. No approval will be granted for qualification or Final (Type) Qualification without full disclosure of the composition, including all ingredients and their percentages, plus tolerances and particle sizes, if applicable.

j. NOSSA N85 will determine if Navy in-house explosive loading validation is required to ensure production safety for contractor developed munitions per reference (g).

6. Action

a. NAVSEA. In the capacity as Lead Systems Command for energetic materials and IM per reference (a), NAVSEA 00V is the approval authority for explosives qualification and Final (Type) Qualification.

b. NOSSA. The Insensitive Munitions Office (NOSSA N85) will:

(1) Review qualification data packages submitted on explosives and either prepare documentation granting qualification for NAVSEA 00V signature or provide a written response citing reasons for denial of qualification, or requesting additional information, within 45 days of receipt of the data package.

(2) Review Final (Type) Qualification requests and either prepare documentation granting Final (Type) Qualification for NAVSEA 00V signature or provide a written response citing reasons for denial of Final (Type) Qualification, or requesting additional information, within 60 days of receipt of the data package.

(3) Issue designations (nomenclature) for qualified and Final (Type) Qualified explosives, as appropriate.

(4) Respond to requests to use an explosive that is not included in table 3 of reference (f).

(5) Update and maintain reference (f).

(6) Maintain the repository of all explosive qualification and Final (Type) Qualification data per the requirements set in Secretary of the Navy (SECNAV) Manual 5210.1 of January 2012.

c. Naval Air Systems Command (NAVAIR). NAVAIR will:

(1) Support and assist NAVSEA to implement this instruction.

(2) Assign a NAVAIR point of contact the responsibility for ensuring that explosives used in NAVAIR applications meet the requirements of this directive.

d. Marine Corps Systems Command (MARCORSYSCOM). MARCORSYSCOM will:

(1) Support and assist NAVSEA to implement this instruction.

(2) Assign a Marine Corps point of contact the responsibility for ensuring that explosives used in Marine Corps applications meet the requirements of this instruction.

(3) Act as the program manager for all Marine Corps Class V (W) inventory that may be transported on Navy ships.

e. Program Managers, Department of Navy (DON) Systems Commands, and Warfare Centers. Program managers, DON Systems Commands, and Warfare Centers will:

(1) Prepare qualification data packages for explosives per enclosure (3) and submit to NOSSA N85 with written concurrence from the Commanding Officer or authorized representative of Naval Surface Warfare Center, Indian Head Explosive Ordnance Disposal Technology Division (NAVSURFWARCENIHEODTECHDIV); Naval Air Warfare Center Weapons Division (NAVAIRWARCENWPNDIV), China Lake; or NAVSURFWARCENDIV, CRANE.

(2) Prepare Final (Type) Qualification data packages per enclosure (4) and submit requests to NOSSA N85.

NA VSEAINST 8020.5D

(3) Provide technical support to NAVSEA and other commands or activities, as required, to implement this instruction

( 4) Provide advisory statements on the processing and safe-handling characteristics of high explosives, propellants, and pyrotechnics for Final (Type) Qualification that have been generated by NAVSURFW ARCENIHEODTECHDIV; NAVAIRWARCENWPNDIV, China Lake; or NA VSURFW ARCENDIV Crane.

7. Records Management

a. Records created as a result of this instruction, regardless of format or media, must be maintained and dispositioned for the standard subject identification codes 1000 through 13000 series per the records disposition schedules located on the Department of the Navy/Assistant for Administration (DON/ AA) Directives and Records Management Division (DRMD) portal page at https://portal.secnav.navy.mil/orgs/DUSNM/DONAAIDRM/Records-and-Information Management/ Approved%20Record%20Schedules/Forms/ Allltems.aspx.

b. For questions concerning the management of records related to this instruction or the records disposition schedules, please contact your local records manager.

8. Review and Effective Date. Per OPNA VINST 5215.17 A, SEA OOV will review this instruction annually around the anniversary of its issuance date to ensure applicability, currency, and consistency with Federal, Department of Defense, Secretary of the Navy, and Navy policy and statutory authority using OPNA V 5215/40 Review of Instruction. This instruction will be in effect for I 0 years, unless revised or cancelled in the interim, and will be reissued by the 10-year anniversary date if it is still required, unless it meets one of the exceptions in OPNA VINST 5215. l?A, paragraph 9. Otherwise, if the instruction is no longer required, it will be processed for cancellation as soon as the need for canc~e· on is known following the guidance in OPNA V Manual 5215. l of May 2016.

c,, Distribution:

Electronic only, via the NAVSEA Intranet Website located at https://navsea.navy.deps.mil.

Enclosure (1)

REFERENCES

Ref: (a) OPNAVINST 8010.13E, Department of the Navy Policy on Insensitive Munitions, 14

January 2014

(b) OPNAVINST 8020.14A, Department of the Navy Explosives Safety Management

Policy Manual, 15 February 2013

(c) NATO STANAG 4170

(d) NATO-AOP-7

(e) NAVSEAINST 8010.5C, Insensitive Munitions Program Planning and Execution, 15 September 2015

(f) SW010-AG-ORD-010

(g) NAVSEAINST 8020.11A, High-Explosives and High-Explosives-Loading of Navy

Non-Nuclear Munitions, 21 January 1992

(h) MIL-STD-1316F, Fuze Design, Safety Criteria for, 18 August 2017

(i) 29 CFR 1910

(j) MIL-STD-2105D, Hazard Assessment Tests for Non-Nuclear Munitions, 19 April

(k) NAVSEAINST 8020.8C, Department of Defense Ammunition and Explosives

Hazard Classification Procedures, 30 July 2012

(l) CPIA PUB 21, Solid Propellant Mechanical Behavior Manual

(m) MIL-STD-286C, Propellants, Solid: Sampling, Examination and Testing, 13 October 2010

(n) MIL-D-21625G, Design and Evaluation of Cartridges for Cartridge Actuated

Devices, 30 November 1993

(o) MIL-D-23615C, Design and Evaluation of Cartridge Actuated Devices, 30 November 1993

(p) MIL-DTL-23659F, Initiators, Electric, General Design Specification for, 18 March

Enclosure (2)

DEFINITIONS

The following definitions are consistent with the common usage within the U.S. Department of Defense and most other U.S. agencies. The terms marked with an asterisk (*) are definitions taken from reference (c) and modified, as appropriate, to identify the responsible authorities and to ensure relevance to the U.S. Navy.

1. Assessment. *An evaluation of the properties of an explosive material, including the results of appropriate tests, to determine its relationship, with particular regard to safety, to other explosive materials already in service use.

2. Booster Explosives. *An explosive material used to augment and transmit the reaction (initiated by the primary explosive) with sufficient energy to initiate a detonation reaction in the main charge high explosive. PBXN-5 and PBXN-7 are examples of qualified booster explosives.

3. Comparison Explosive. *An in-service explosive with proven safety characteristics that has properties used to assess the relative safety and suitability of a new explosive intended for use in a similar role.

4. Explosive. *A substance (or mixture of substances) capable by chemical reaction of producing gas at such temperature and pressure as to cause damage to the surroundings.

Included are pyrotechnic substances even though they may not evolve gases as they react. The term “explosive” thus, includes all solid and liquid materials variously known as high explosives and propellants, together with igniter, primer, initiatory, and pyrotechnic (e.g., illuminant, smoke, delay, decoy, flare, and incendiary) compositions.

5. Final (Type) Qualified Explosive. Energetic material that has been formally approved by NAVSEA 00V for service use in a specific application or weapon system. The approval is based, in part, on an assessment of the explosive as part of the design of the item or configuration in which it will be used and for which it has been judged by NAVSEA 00V to be safe and suitable for use by the Navy. This approval step is required, and the data must be presented to the Weapon System Explosives Safety Review Board before a munition is approved for service use.

6. High Explosive. Substances or mixtures that, in their application as primary, booster, or main charges in warheads or other applications, are required to detonate.

7. Main Charge Explosive. An explosive material used as the final charge and functioned to obtain the desired effect in the end-item application. PBXN-103, PBXN-110, PBXN-107, and PBXN-9 are examples of qualified main charge explosives.

2 Enclosure (2)

8. Munition. An assembled ordnance item that contains explosive material(s) and is configured to accomplish its intended mission.

9. New Explosive. *This term encompasses:

a. An explosive material not previously qualified.

b. An explosive material for which the existing specification defining its composition, its material constituents, the source of these constituents, or the process by which the composition is prepared has been modified.

c. An explosive material resulting from a change in manufacturer or manufacturing location.

d. An explosive material used in a role for which it has not already been qualified (e.g., a booster explosive used as a main charge or a propellant used as a high explosive).

10. Primary Explosives. *A substance or mixture of substances used to initiate a detonation or a burning reaction. These primary explosives are sensitive to heat, impact, and shock and, in warheads, are separated from the booster explosive by the fuze, exploder, or safety-and-arming device as specified in reference (h). Lead styphnate, dextrinated lead azide, and DXN-1 are examples of primary explosives.

11. Propellant. A substance or mixture of substances used for propelling projectiles and missiles or to generate gases for powering auxiliary devices. When ignited, propellants burn at a controlled rate to produce quantities of gas capable of performing work, but in their application they are required not to undergo deflagration-to-detonation transition.

12. Pyrotechnics. *Substances or a mixture of substances that, when ignited, undergo an energetic chemical reaction at a controlled rate intended to produce, on demand and in various combinations, specific time delays or quantities of heat, noise, smoke, light, or infrared radiation.

Pyrotechnic compositions may be used to initiate burning reactions such as in igniters.

Pyrotechnic compositions may be qualified for a specific role(s) such as time delay, illuminating flare, etc. A qualification status is not valid for other pyrotechnic roles for which the composition has not been assessed.

13. Qualification. *The assessment of the explosive material by NAVSEA 00V according to this instruction to determine whether it possesses properties which make it safe and suitable for consideration for use in its intended role.

14. Qualified Explosive. *An explosive material that has successfully completed the qualification process described in this instruction and has been formally approved by NAVSEA for use in munitions development, product improvement, or other programs leading to eventual

3 Enclosure (2) service application. This is an intermediate risk reduction stage prior to Final (Type) Qualification.

15. Reference Standard Explosive. An explosive that has consistent and sufficiently well-defined properties to enable its use for the calibration of a test apparatus. The explosive nominated as a reference standard, together with its lot number when appropriate, must be identified on the relevant national test information sheet.

Enclosure (3)

QUALIFICATION PROCEDURES FOR EXPLOSIVES

1. General

a. The process for qualification of an explosive is described within this enclosure.

b. The qualification data package for an explosive must contain sufficient supporting data to show that it is judged to be safe and suitable for consideration in development, product improvement, or other programs leading to eventual service applications. Results of tests conducted per U.S. ratified STANAGs are recognized as sufficient proof of level of sensitivity when compared to a recognized comparison explosive.

c. Prior to the beginning of testing, a review of the test plan by NOSSA N85 is advised.

2. Required Documentation

a. The qualification data package must include:

(1) Mandatory data according to this instruction, including tables I, II, and III.

Additional data may be required or mandatory data may be waived by NOSSA N85 on a case-by-case basis. To establish any additional requirements, a review of the generated data with NOSSA N85 prior to submission of the qualification data package is recommended.

(2) Data in a format per figure 1 of this enclosure for inclusion in reference (f).

(3) A draft of the material specification or STANAG. The specification must include the full composition, including all ingredients and their percentages, as well as their particle sizes and permissible tolerances, if applicable. The samples used for the qualification testing must comply with the specification and must be made by the approved method of manufacture.

(4) A justification for qualification of explosive compositions, citing a significant improvement in safety, performance, processability, environmental characteristics, or cost over currently qualified explosives. In order to control the proliferation of these compounds, only explosives that demonstrate a significant advantage over an existing explosive will be included in table 3 of reference (f). Qualification may be denied without data showing a significant advantage over an existing explosive.

(5) A draft of a comprehensive technical report on the qualification testing of the explosive (methods and results).

(6) A draft safety data sheet per reference (i).

2 Enclosure (3)

(7) Recommendation for qualification by the Commanding Officer or authorized representative of the submitting activity.

(8) A statement on the productibility of the explosive based on availability of material, properties, mix histories, production batch size, and overall production risk assessment.

b. A comprehensive technical report on the qualification testing of the explosive, published by the requesting organization within 6 months of qualification, is recommended.

3. Qualification Test Data

a. Mandatory data and assessments for high explosives, solid propellants, and pyrotechnics are listed in table I. The test procedures and equipment are defined in table II and references (d) and (j). Qualification tests will be performed on fully cured samples. In addition, NOSSA N85 must concur that the test procedure and apparatus are adequate for qualification purposes.

b. Test requirements for liquid, slurry, and gel explosives are addressed in paragraph 8 of this enclosure.

c. Accelerated aging studies must be included in the qualification testing of new explosives.

Table III shows the required aging protocols. Deviations from the aging and test matrix in table III, or assessments in lieu of testing, must be approved by NOSSA N85 prior to the start of the aging program. Test procedures and data evaluation will be conducted as described in reference (d). The data, as well as safe-life and service-life predictions based on changes in the explosive properties, will be submitted with the qualification package. Pass-fail criteria for the mechanical integrity of high explosives differ substantially from those of rocket propellants, depending on projected applications (e.g., penetrator warhead, directional warhead, shaped charge, projectile fill). In predicting the expected service-life, several scenarios may have to be considered. Because of the inherent sensitivity and intended end-item application of primary high explosives and some pyrotechnic compositions, acceptance criteria for these materials are largely determined from thermal stability data. A low temperature aging study at 25 °C with humidity control will be started with the qualification testing with final results reported in the Final (Type) Qualification package. Interim results will be reported in the qualification package.

d. Test data submitted to NOSSA N85 in the qualification package must be generated on explosive samples taken from a batch made using representative production techniques.

4. Generic IM Tests. IM testing per reference (j) conducted in generic test hardware is recommended for qualification. A review of the test plan by NOSSA N85 is suggested.

5. Hazard Classification Tests. Hazard classification testing (UN Series 3) will be performed per reference (k).

3 Enclosure (3)

6. Additional Tests. Additional tests listed in references (d), (k), and (l) provide desirable background information and may be requested by NOSSA N85 on a case-by-case basis for use in assessing safety and suitability for service use.

7. Procedures and Additional Data Requirements for Solid Explosives Qualification

a. Primary explosives will be tested per reference (d).

b. Booster Explosives:

(1) Qualification testing of booster explosives will be conducted per reference (d), which also assigns pass-fail criteria. NOSSA N85 may waive some of these criteria based on overall material characteristics or other circumstances. In such cases, the qualification record for the explosive will note any special restrictions resulting from such an action. Failure to pass one or more of these criteria will generally prevent the qualification of a booster explosive.

(2) The qualification request will contain a comparison of the results of the mandatory tests with those obtained from at least two approved booster explosives listed in reference (f).

(3) Qualification acceptance as a booster explosive does not automatically imply compliance with reference (h). In order for a booster explosive to be included in table 1 of reference (h), it must meet the additional requirements of section 5.3.2 of reference (h).

c. Main Charge Explosives:

(1) Qualification testing of main charge explosives will be conducted as described in reference (d), which also assigns pass-fail criteria. Failure to pass one or more of these criteria will generally prevent the qualification of a main charge explosive. NOSSA N85 may waive some of these criteria based on overall material characteristics or other circumstances. In such cases, the qualification record for the explosive will note any special restrictions resulting from such an action.

(2) The qualification request will contain a comparison of the data from the required tests with results obtained from at least two approved main charge explosives and one booster explosive listed in reference (f).

d. Solid propellants will be tested per procedures listed in references (d), (k), (l), and (m).

The data will be compared with those generated on at least two similar solid propellants from reference (f).

e. Pyrotechnics will be tested per reference (d).

4 Enclosure (3)

8. Qualification of Liquid, Gel, and Slurry Explosives

a. Mandatory tests for qualification are determined on a case-by-case basis. For novel compositions or applications, new tests may be developed and employed when approved in advance by NOSSA N85. Tests listed in reference (d) are generally required to evaluate the overall safety characteristics of liquid, gel, and slurry explosives.

b. A qualification test plan for liquid, gel, and slurry explosives must be approved by NOSSA N85 prior to commencement of testing. The possible need for and extent of an aging protocol will be established in cooperation between the program manager and NOSSA N85.

Table I. Mandatory Qualification Tests or Assessments.

Tests Primary Booster Main Charge

Solid Propellant

Pyrotechni c

Impact Sensitivity X X X X X Friction Sensitivity X X X X X Electrostatic Sensitivity X X X X X Vacuum Stability X X X X X Ignition Temperature X X X X X Self-Heating X X X Thermal Stability X X X X Small Scale Burn X X X X Shock Sensitivity X X X Cap X X X Detonation Velocity X X X 1/ Critical Diameter X X X 1/ Mechanical Properties X 2/ X 2/ X Stabilizer or Anti-Oxidant Level X X X Growth X 3/ X 3/ Exudation X 4/ X 4/ X 4/ Burn Rate X Toxicity X X X X X Compatibility X X X X X

NOTES:

1/ Required if the propellant is detonable.

2/ Required for Plastic Bonded Explosive (PBX)-type explosives.

3/ Required for melt-cast explosives.

4/ Required for melt-cast explosives and explosives containing energetic binders or plasticizers.

5 Enclosure (3)

Table II. Qualification Test Methods.

Tests AOP-7 U.S. Method 1/ STANAG UN Test Series

Impact Sensitivity 201.01.001/002/003/004/00 5 4489 3a

Friction Sensitivity 201.02.001/004/005/006/00 8 4487 3b

Electrostatic Sensitivity 201.03.001/002/003 4490 Vacuum Stability 202.01.001/022 4556 Ignition Temperature 202.01.007/008/020 4515 Self-Heating 202.01.012 Thermal Stability 202.01.013 3c Small Scale Burn 202.01.014 3d Shock Sensitivity 201.04.001/002/004/005 4488 7b Cap 201.04.009 7a Detonation Velocity 302.01.001 Critical Diameter 302.01.003 Mechanical Properties 102.01.001 4506/4443 Stabilizer or Anti-Oxidant Level 2/ Growth 202.01.011 Exudation 202.01.010 Burn Rate 302.02.001/002 Toxicity 3/ Compatibility 203.01.001

NOTES:

1/ See reference (d) for recommendations on which specific test methods are most appropriate for each explosive type.

2/ Composition analysis.

3/ Assessment of the ingredients, processing, and combustion by-products.

6 Enclosure (3)

Table III. Aging Protocols.

Explosive Type

Booster / Main Charge / Solid Propellant

Primary Pyro

Compositions NOT Containing Nitrate

Esters or Other Energetic Binders or

Plasticizers

Compositions Containing Nitrate

Esters or Other Energetic Binders or

Plasticizers

Aging Conditions 1/ 60 °C for 8 months 70 °C for 6 months

50 °C for 12 months 60 °C for 8 months

70 °C for 12 months

70 °C for 12 months

Impact Sensitivity

60 °C at 1, 2, 4, 6, & 8 months 70 °C at 1, 2, 4, & 6 months

50 °C at 1, 3, 6, 9, & 12 months 60 °C at 1, 2, 4, 6, & 8 months at 6 & months at 6 & months

Friction Sensitivity

60 °C at 1, 2, 4, 6, & 8 months 70 °C at 1, 2, 4, & 6 months

50 °C at 1, 3, 6, 9, & 12 months 60 °C at 1, 2, 4, 6, & 8 months at 6 & months at 6 & months

Ignition Temperature

60 °C at 1, 2, 4, 6, & 8 months 70 °C at 1, 2, 4, & 6 months

50 °C at 1, 3, 6, 9, & 12 months 60 °C at 1, 2, 4, 6, & 8 months at 6 & months at 6 & months

Shock Sensitivity 2/ 60 °C at 8 months 70 °C at 6 months

50 °C at 12 months 60 °C at 8 months

Mechanical Properties 3/

60 °C at 1, 2 ,4, 6, & 8 months 70 °C at 1, 2, 4, & 6 months

50 °C at 1, 3, 6, 9, & 12 months 60 °C at 1, 2, 4, 6, & 8 months

Stabilizer or Anti- Oxidant Level 4/

60 °C at 1, 2, 4, 6, & 8 months 70 °C at 1, 2, 4, & 6 months

50 °C at 1, 3, 6, 9, & 12 months 60 °C at 1, 2, 4, 6, & 8

Growth or Exudation 50 °C at 12 months

60 °C at 8 months

Burn Rate 5/ 60 °C at 8 months 70 °C at 6 months

50 °C at 12 months 60 °C at 8 months

Cube Cracking 6/ 60 °C at 1 month

Hot Wire Initiability at 6 &

7 Enclosure (3)

Priming Ability at 6 &

Table III. Aging Protocols. - Continued

NOTES:

1/ Aged in sealed containers. Compositions based on polyester binders will be aged under controlled humidity [30 percent relative humidity (RH)]. All other compositions have no humidity control requirement.

2/ Gun propellants excluded.

3/ Gun propellants: high rate compressive strength. All other solid propellants and PBX-type explosives: uniaxial at three temperatures.

4/ When applicable.

5/ Solid propellants only.

6/ Gun propellants excluded. Boosters: 3-inch cube. All others: 6-inch cube

8 Enclosure (3)

1. DEVELOPMENTAL EXPLOSIVE NAME: [e.g., PBXW-11, PBXC-129] [include specification number]

2. EXPLOSIVE NOMINAL COMPOSITION:

Ingredient Wt%

3. POSSIBLE PURPOSE: [e.g., Special purpose flare composition]

4. ADVANTAGES: [e.g., Ease of processing, sensitivity features]

5. EXPLOSIVE PREPARATION INSTRUCTIONS:

6. QUALIFICATION TESTS: [Note: List of tests may be different from below depending on type of explosive. See table I.]

a. Small Scale Tests

Test Result Pass Criteria Impact Sensitivity (50% point)

[Also report result of standard]

Cap Test Gap Test [Also report type of test; e.g., Large Scale Gap Test, Small

Scale Gap Test] Thermal Stability Ignition/Unconfined Burn Vacuum Stability Self-Heating [Report critical temperature for a given mass and geometry] Friction Sensitivity [Also report result of standard] Electrostatic Sensitivity [Also report result of standard] Detonation Velocity [Report density] Critical Diameter [Report density] Compatibility Data Burn Rate Growth and Exudation

Figure 1. Format for Submission of Qualification Test Data to be Included in NAVSEA SW010-AG-ORD-010.

9 Enclosure (3)

b. Generic Tests

Test Result Fast Cook-Off Slow Cook-Off Bullet Impact Fragment Impact

7. AGING CHARACTERISTICS:

a. Rocket Propellant, Booster/Main-Charge High Explosives: [Note: List of tests may be different from below depending on type of explosive. See table III.]

Test Result Acceptance Criteria Ignition Temperature [Differential Thermal Analysis(DTA): 2 gms, 1 °C/min, baseline/after completion of accelerated aging]

No substantial changes.

Technical assessment required.

Impact (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Friction (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Shock Sensitivity (baseline/as specified in table III)

No substantial changes.

Technical assessment required.

Cube Cracking Test (X-ray results)

No fissures after 30 days at 60 °C.

Technical assessment required.

Burn Rate (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Growth and Exudation (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Stabilizer/Anti-Oxidant Level (% change at elevated temperatures)

No substantial changes.

Technical assessment required.

in NAVSEA SW010-AG-ORD-010 – Continued.

10 Enclosure (3)

Safe (Shelf) Life Prediction at 25 °C (based on extrapolated high temperature depletion rates)

20 years with at least 20% stabilizer remaining.

Technical assessment required.

Mechanical Properties (% change at elevated temperatures)

Changes >20% may require further tests.

Technical assessment required.

Safe Use (Service) Life Predicted at 25 °C (based on extrapolated mechanical properties, cube cracking results, shock values, and mechanical properties)

≤20% change in mechanical properties post-cure (30 days) or when intersecting anticipated specification limits.

No substantial changes in shock sensitivity. No fissures after 30 days at 60 °C.

b. Gun Propellants

Ignition Temperature (DTA:

2 gms, 1 °C/min, baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Impact (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Friction (baseline/after completion of accelerated aging)

No substantial changes.

Technical assessment required.

Stabilizer/Anti-Oxidant Level (% change at elevated temperatures)

No substantial changes.

Technical assessment required.

Safe (Shelf) Life Prediction at 25 °C (based on extrapolated high temperature depletion rates)

20 years safe storage at 25 °C.

Technical assessment required.

Mechanical Properties (compressive strength, % change at elevated temperatures)

Changes >20% in failure modulus may require additional tests.

11 Enclosure (3)

c. Primary Explosives

Impact No substantial changes.

Technical assessment required.

Friction No substantial changes.

Technical assessment required.

Hot Wire Initiability No substantial changes.

Technical assessment required.

Priming Ability No substantial changes.

d. Pyrotechnics

Impact No substantial changes.

Technical assessment required.

Friction No substantial changes.

Technical assessment required.

Ignition Temperature No substantial changes.

Technical assessment required.

8. ENVIRONMENTAL/TOXICITY ANALYSIS: [Components/formulation/combustion products]

9. OTHER TESTS: [Variable Confinement Cook-Off Test, Growth and Exudation, etc.]

10. BATCH SIZE: [Provide maximum batch size produced]

11. PHYSICAL PROPERTIES:

a. Physical state (solid, liquid, gel) at ambient conditions

b. Color

12 Enclosure (3)

c. Density

d. Hardness

e. Vapor pressure

f. Boiling point

g. Freezing point

h. Glass transition temperature

i. Coefficient of thermal expansion

12. ADDITIONAL DATA/COMMENTS/INFORMATION:

13. REFERENCES:

Enclosure (4)

FINAL (TYPE) QUALIFICATION PROCEDURES FOR EXPLOSIVES

1. General

a. The process for Final (Type) Qualification of an explosive is described within this enclosure.

b. Data required for Final (Type) Qualification of an explosive will be submitted to NOSSA N85 by the Office of Primary Responsibility and must contain sufficient supporting data to show that the explosive is judged, by the submitting activity, to be safe and suitable in the intended application.

2. Required Documentation. The Final (Type) Qualification package must include:

a. Mandatory data according to this instruction, including table I. Additional data may be required or mandatory data may be waived by NOSSA N85 on a case-by-case basis. To establish any additional requirements, a review of the generated data with NOSSA N85 prior to submission of the Final (Type) Qualification data package is recommended. Planned tests, including test configurations, any deviations from mandatory requirements, and required additional tests will be approved by NOSSA N85 in the IM test plan prior to the commencement of testing.

b. Data formatted per figure 1 of this enclosure for inclusion in reference (f).

c. A statement of the degree of compliance with references (e) and (j) with supporting data.

This data should include the results of an IM test plan that has been approved by NOSSA N85.

The supporting data may also include a Threat Hazard Assessment, minutes or reports from the Munitions Reaction Evaluation Board, and munition Programs of Action and Milestones included in the program manager’s IM Strategic Plan.

d. Approved finalized materials documentation or description such as materials specification, STANAG, etc.

e. Approved finalized Navy Munitions Document (NMD) for booster and main-fill high explosives per reference (g). All units used for Final (Type) Qualification testing must be manufactured to the requirements of the approved finalized NMD. Allowance will be made for circumstances requiring Final (Type) Qualification data for generation of the NMD.

f. An advisory statement on processing and safe handling characteristics. NOSSA N85 will determine if Navy in-house loading validation is required. If so, technical representatives of a specified Navy pilot plant will witness processing operations at the vendor facility prior to providing an advisory statement.

2 Enclosure (4)

g. A final hazard classification or submission of a final hazard classification data package to NOSSA N85 per reference (k).

h. Final draft of a comprehensive technical report.

i. Recommendation for Final (Type) Qualification signed by the Commanding Officer of the submitting activity or by an authorized representative.

3. Mandatory Test Data

a. For primary explosives in the end-item usage (e.g., in arm-fire devices, exploders, and safety-and-arming devices), the requirements specific to these devices (e.g., reference (h) for safety-and-arming devices) must be met and a compliance matrix submitted. In addition, testing requirements listed in table I will be met or assessed as applicable.

b. Mandatory data and assessments listed in table I apply to explosives in all-up surface, air, and underwater launched non-nuclear ordnance and explosive devices. Some tests may be performed on subsystems with prior approval by NOSSA N85 as long as extrapolation of vulnerability characteristics to all-up ordnance can be justified.

c. For explosives in Cartridges, Cartridge Actuated Devices (CAD), and Propellant Actuated Devices (PAD) in the end-item usage, Final (Type) Qualification must be performed in the same configuration as will be used in the intended role and following procedures listed in references (j), (n), (o), and (p). Testing per references (n), (o), and (p) may take the place of some of the test requirements of table I with prior approval by NOSSA N85.

d. Chemical compatibility testing of the explosive being considered for Final (Type) Qualification will be conducted between the explosive and all materials (both energetic and inert) with which it may come in contact in production and in the end-item configuration.

e. Assessments may be used to satisfy testing requirements in some instances with prior concurrence from NOSSA N85. Justification for the assessment with supporting data will be included in the Final (Type) Qualification data package. Any information requested on an assessment basis may be changed to a requirement of actual testing of the all-up round if deemed necessary by NOSSA N85.

f. Final results from low temperature with humidity aging studies as discussed in enclosure (3), paragraph 3d will be reported when completed.

g. Batch analysis data for the explosives used in the mandatory Final (Type) Qualification tests (table I) will be reported. The explosive batch size that is used to fill the test hardware must represent the explosive batch size that is planned to be used in production. All production-level mixing and loading procedures must be followed when manufacturing test units for Final (Type)

3 Enclosure (4)

Qualification tests. The use of any non-production representative batch size or processing methods must be approved in advance by NOSSA N85.

Table I. Mandatory Final (Type) Qualification Tests.

Tests Primary Booster Main Charge

Solid Propellant Pyrotechnic

Temperature & Humidity X X X X X Vibration X X X X X 40-Foot Drop X X X X X 5-Foot Drop X - - - - Fast Cook-Off X X X X X Slow Cook-Off X X X X X Bullet Impact X X X X X Fragment Impact X X X X X Sympathetic Detonation X X X X X Shaped Charge Jet X X X X X Jolt X X - - X Jumble X X - - X Compatibility X X X X X Temperature/Humidity Aging

- X X X -

4 Enclosure (4)

1. EXPLOSIVE LISTING:

Application Nomenclature*

Application Drawing/

Specification*

Qualified Explosive Name**

Qualified Explosive

Specification**

Explosive Weight

* List the application nomenclature and drawing or specification for the munition, component, or subcomponent (e.g., primer, detonator, booster, lead, etc.), as applicable, that contains an explosive material.

** List all explosive materials that are being Final (Type) Qualified in the munition by application. Include specification number. If not previously qualified, provide explosive nominal composition (by ingredient and weight percent).

2. FINAL (TYPE) QUALIFICATION TEST DATA:

Final (Type) Qualification Test Data (If Applicable) Reaction

Temperature & Humidity Vibration 40-Foot Drop 5-Foot Drop Fast Cook-Off Slow Cook-Off Bullet Impact Jolt Jumble Fragment Impact Sympathetic Detonation Spall Impact Shaped Charge Impact

3. CHEMICAL AND PHYSICAL COMPATIBILITY DATA:

4. AGING CHARACTERISTICS: [Report final aging results of low temperature with humidity aging studies using the format provided for explosive qualification in enclosure (3).]

5. REFERENCES:

Figure 1. Format for Submission of Final (Type) Qualification Test Data to be Included in NAVSEA SW010-AG-ORD-010.