Innovative Materials and Coatings for Lightweight Low-Cost Modular Ammunition Packaging

Large caliber ammunition is currently packaged using techniques developed during World War II resulting in environmental performance, handling, and other operational problems. Modular plastic containers are uniquely well suited to low-cost packagingdesigned for efficient shipping and delivery. However, suitably inexpensive plastics do not currently meet the demanding U.S. military requirements. Advanced plasma spray techniques make it possible to inexpensively apply closely controlled and tenaciousmetallic coatings to plastics. Such coatings can provide environmental protection and significantly enhanced permeability, flammability, and outgassing performance. We propose to combine these two technologies to provide, by careful selection ofcomplementary materials and process parameters, the flexibility and cost advantages of lightweight plastic packaging with performance approaching that of heavy metal containers.During Phase I, we will analyze the Marine Corps' ammunition packaging requirements and constraints in detail, select appropriate materials and coatings, and fabricate and test material/coating samples to demonstrate the improved performance of suitablydesigned material/coating combinations. During Phase II, we will design modular, easily handled plastic packaging, test these material/coating combinations against the full spectrum of requirements, and fabricate prototype containers for evaluation by theMarines and the Defense Ammunition Center. Successfully overcoming current plastic packaging shortfalls will make it possible to exploit the unique potential of low-cost lightweight plastics to significantly improve ammunition packing performance and handling efficiency. This, in turn, opensopportunities to reduce the time and cost in shipment from depot to battery, and to significantly improve the operational flexibility and shoot and scoot movements.