Pultrusion-Based Production of Next-Generation Composite Ammunition Containers

KaZaK Composites proposes to investigate composite and metal/composite hybrid ammunition containers optimized for minimum cost production using highly automated pultrusion processing for the main structural tube and perhaps other components of thecontainer. Pultrusion, the composite processing equivalent of aluminum extrusion, is capable of continuously making constant cross section parts with very little labor content at the rate of several feet per minute. Other conceivable composite processingmethods are more costly because they make tubes one at a time. In addition to conventional composite designs, KCI will investigate a unique macro-composite structural concept that we have used with success in the past to produce 3.5-inch diameter militaryaircraft carrier stanchions with an unusual combination of high stiffness, strength, and extremely high impact damage resistance. These same properties are desirable in a composite ammunition container. In Phase I KCI will develop a number of candidatedesign concepts, then after appropriate analysis, trade study and discussion with the Army, select one or two for further investigation. Composite hardware samples of key structural components will be fabricated and subjected to bending and impact testing.A concept for a thermal fuse to prevent container overpressure in a fire will also be evaluated. There are many applications for low cost, damage resistant structural tubing. KCI is actively involved with the development of pultruded composite stanchionsfor Naval applications, as well as pultruded composite energy absorbing utility poles. Both these programs will directly benefit from the new design and processing concepts conceived and put into practice during the proposed program. In addition to the2.75