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This white paper is authored by Los Alamos National Laboratory and BAE Systems.
Ramos, Kyle, et al. Utilization of the Focus Beam Reflectance Measurement (FBRM) Probe in Explosive Processing. Energetic Materials Technology Working Group Symposium 2024, 2024-05-13 (Oslo, Norway), 12 Aug. 2024.
The manufacturing of modern explosives requires meeting extreme material requirements, where even slight variations in particle size distribution (PSD) can compromise performance and safety. Traditional offline measurement techniques often rely on small samples that may not accurately represent large production batches. This white paper details a breakthrough in energetic material processing through the successful implementation of Focused Beam Reflectance Measurement (FBRM) technology.
The Critical Link Between Structure and Safety
- Performance Sensitivity: Variations in the microstructure and PSD of energetic constituents significantly impact an explosive's pressing properties and mechanical strength.
- Safety Risks: Lot-to-lot variability in materials like PBX 9501 has been linked to measurable differences in shock sensitivity, which can be critical in accident scenarios.
- The Data Gap: Historically, it was difficult to quantitatively prove the relationship between PSD and performance because measurements were performed offline on gram-scale aliquots.
By installing a ParticleTrack FBRM probe directly into a 120-gallon vacuum still, researchers have enabled continuous, real-time tracking of particle evolution.
Key Features of FBRM Integration:
- Instant Process Decisions: Operators can now make data-driven decisions on exactly when to add lacquer, how long to age a mixture, and when to begin distillation.
- Ensured Uniformity: The probe monitors the disappearance of micronized HMX conglomerations during mixing, ensuring the material is fully dispersed before proceeding.
- A "Digital Fingerprint": FBRM generates a quantitative record of successful formulations, creating a template for future batches to ensure robustness and repeatability.
- Intuitive Operation: Pilot plant operators found the technology so beneficial that they shifted from manual "dip cup" inspections to relying on real-time data trends.
FBRM technology is a vital step toward mastering the Processing-Structure-Property-Performance (PSPP) relationship. Precise control over crystal size and defects has already demonstrated the potential to reduce shock sensitivity by 300% in certain regimes. By rendering these advanced formulation methods into practical, production-scale tools, the industry can achieve a major advancement in munitions safety and reliability.
