Low Cost Plastic, Composite and Metal Hybrid Next-Generation Ammunition Containers

KaZaK Composites and the University of Massachusetts-Lowell propose to investigate composite, thermoplastic and metal hybrid-material ammunition containers optimized for reduced weight, reduced volume and minimum cost. KCI will lead the design effort, aswell as the metal and composite component evaluations. UML will focus on thermoplastic component evaluations. Designs making maximum use of highly automated manufacturing technologies such as composite pultrusion and thermoplastic injection molding will beemphasized to minimize touch labor for production. 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 military aircraftcarrier stanchions with an unusual combination of high stiffness, strength, and extremely high impact damage resistance. In Phase I KCI will develop a number of candidate design concepts, then after appropriate analysis, trade study and discussion with theNavy, select one or two for further investigation and component demonstration. Composite hardware samples of key structural components will be fabricated and subjected to bending and impact testing. A concept for a thermoplastic end closure that can serveas 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 stanchions for Navalapplications, as well as pultruded composite energy absorbing utility poles. Both these programs will directly benefit from the new design and processing concepts conceived of and put into practice during the proposed program. In addition to the specificround selected for packaging studies in Phase I and development in Phase II, military applications include packaging for a large variety of ammunition. Derivative packaging can also be used commercially for shipping and storage of high value hardware.