Non-Carcinogenic, Reduced-Toxicity Fuel/Catalyst Replacement for the F-16 EPU, Phase II

The emergency power units (EPU) on the F-16 and U-2 aircraft use a hydrazine-water mixture known as H70 to generate hydraulic and electrical power. Hydrazine is flammable, corrosive, poisonous, and carcinogenic, so the Air Force would like to replace it. The use of alternative safer fuels will enable the Air Force to realize a significant cost savings by eliminating the need for high-cost support equipment and training for maintainers. In this project, using Ultramet’s patented catalyst technology, a drop-in replacement gas generator for the F-16 EPU will be developed. Instead of hydrazine-based propellant, the new gas generator will use a non-toxic propellant such as DMAZ (2-dimethylaminoethyl azide). In Phase I, reactivity of DMAZ with Ultramet’s patented catalyst was demonstrated in 20 msec at temperatures down to -48°C (the lowest temperature tested). The Air Force stakeholders have been identified (the 419th Supply Chain Management Squadron, Engineering [419 SCMS/GUEA, Hill AFB, UT] and the F-16 System Program Office [AFLCMC/WWM]), as well as the manufacturer of the current EPU (Honeywell). In Phase II, the basic igniter design will be refined to accommodate the flow rate and throughput required by the Air Force, and full-scale testing of the gas generator will be performed.