dod mems fuze reliability evaluation...dod mems fuze reliability evaluation 59th annual ndia fuze...

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DISTRIBUTION A. Approved for public release: distribution unlimited. DoD MEMS Fuze Reliability Evaluation 59 th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5 th 2016, Open Session IVA, 10:20 Taylor T. Young NSWC IHEODTD 301-744-1103 [email protected] Jeffrey Smyth U.S. Army ARDEC Picatinny Arsenal RDAR-MEF-F Fuze Division [email protected]

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Page 1: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

DISTRIBUTION A. Approved for public release: distribution unlimited.

DoD MEMS Fuze Reliability Evaluation

59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20

Taylor T. Young

NSWC IHEODTD 301-744-1103

[email protected]

Jeffrey Smyth U.S. Army ARDEC Picatinny Arsenal

RDAR-MEF-F Fuze Division [email protected]

Page 2: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

2 DISTRIBUTION A. Approved for public release: distribution unlimited.

MEMS Safe and Arm

Set-back Lock

Command Lock

Slider

Initiator

Arming Micro Motor

Micro Detonator

• MEMS S&A offers the potential for small volume, low cost, and low energy. • NSWC IHEODTD has nearly two decades of silicon/SOI MEMS design, fabrication,

and packaging experience. • Safety locks: integrated micromachined and command release architectures • Arming: Environmentally derived and command architectures • All non-explosive components fabricated on SOI wafers using established semi-

conductor processes.

Page 3: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

3 DISTRIBUTION A. Approved for public release: distribution unlimited.

MEMS Applications Hypervelocity Projectile 40 mm Grenade

High Reliability DPICMS Replacement (HRDR) Flight Controlled Mortar

Page 4: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

4 DISTRIBUTION A. Approved for public release: distribution unlimited.

Explosive Train Reliability

• MEMS intentionally pushes the lower limits of explosive component size. We want the smallest size detonators and leads that will work reliably.

• Target programs have strict reliability requirements. This is particularly true for HRDR which must comply with OSD’s policy of <1% UXO for cluster munitions.

Page 5: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

5 DISTRIBUTION A. Approved for public release: distribution unlimited.

Explosive Train Overview • Studying the explosive trains of both the Navy

and Army MEMS Fuze

• Both designs have been demonstrated to TRL6

• Navy Design – Vaporizing metal foil bridge initiator

fabricated onto the cap chip – Pressed silver azide pellet assembled with

the MEMS S&A chip drives a flyer to initiate an explosive ink output lead

– Lead make 90° turn and initiates a booster

• Army Design – Metal foil bridge – Deposited energetic ink drives small flyer

into explosive ink transfer charge – Transfer charge makes 2 90 ° turns and

initiates output lead

μDetonator Package

Output to Booster

Page 6: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

6 DISTRIBUTION A. Approved for public release: distribution unlimited.

Navy Explosive Train (Basics)

MEMS Microdetonator Silver Azide

Booster Charge – RSI-007/PBXN-5

Lead –EDF-11

MEMS Chip

Base Chip

Cap Chip

Secondary Lead (EDF-11)

RSI-007

Flyer Plate

HE-to-HE or

Flyer Contact

Page 7: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

7 DISTRIBUTION A. Approved for public release: distribution unlimited.

Army Explosive Train (Basics)

MEMS Microdetonator

Energetic Ink

Booster Charge – EDF-11

Lead – EDF-11

MEMS Chip

Base Chip

Cap Chip

Lead (EDF-11)

Booster

(ED

F-11)

HE-to-HE Contact

Flyer Plate

Both detonators use stainless steel flyer plates

US Army AREDEC also has a MEMS Fuze effort.

Uses LIGA metal MEMS processes.

Page 8: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

8 DISTRIBUTION A. Approved for public release: distribution unlimited.

Brute force methods

Brute force demonstrations requires excessive number of shots to prove reliability. 99.9% Reliability @ 95% CL: 3000 Shots

0.7

0.75

0.8

0.85

0.9

0.95

1

10 100 1000 10000 100000

Rel

iabi

lity

Number of Shots Without Failures

0.00001

0.0001

0.001

0.01

0.1

1

1 10 100 1000 10000 100000 1-

Rel

iabi

lity

Number of Shots Without Failures

Binomial Reliability at 95% Confidence Level (one sided)

100 shot test series only demonstrates reliability to 97% (@ 95% CL)

Extremely expensive and becomes impractical for an evolving design

Page 9: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

9 DISTRIBUTION A. Approved for public release: distribution unlimited.

Background – Probabilistic Hugh James Space

0 0.5 1 1.5 2 2.5 30

0.5

1

1.5

2

2.5

3

3.5

4

Σ = u2/2

E=P

u τ

50% reliability1% reliability99% reliability

Increasingreliability

1/J=Ec/E+Σc/Σ

Ec (critical minimum energy) & Σc (critical minimum ‘power’) are defined by the acceptor explosive material. E & Σ can be calculated from variable flyer and gap tests and inherent explosive properties.

Data can better be used to evaluate a family of similar designs, provide more insight into the system and can be used to optimize designs

Hugh James formalism can be used to map out statistical response of acceptor explosive

Variation in Response of Acceptor

Variation in Response of Donor

Overlap – Probability of Failure

These methods were developed at AWE and LLNL and implemented at AFRL.

Page 10: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

10 DISTRIBUTION A. Approved for public release: distribution unlimited.

Detonator Characterization

MEMS flyer velocities can be measured with PDV

Variability will be present in any system Need to shoot a sufficient number (100+) to fit to a statistical distribution. Exact number of shots needed depends on how quickly tails of distribution die off.

PDV system can also be used to measure pressure time histories for contact detonation interfaces.

Page 11: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

11 DISTRIBUTION A. Approved for public release: distribution unlimited.

PDV Results - Navy

11

48 shots analyzed to date. Additional shots ongoing.

Standard deviation 3.7% of mean value.

Page 12: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

12 DISTRIBUTION A. Approved for public release: distribution unlimited.

Flyer Measurements in HJ Space

E

Σ

Navy MEMS Data

Army MEM data

The Navy design uses a larger diameter flyer

Page 13: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

13 DISTRIBUTION A. Approved for public release: distribution unlimited.

Previous EDF-11 Threshold Measurements

E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data

LLNL has made previous threshold measurements on EDF-11

These measurements were made at EFI length scales, and would be lower at larger spot sizes.

Page 14: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

14 DISTRIBUTION A. Approved for public release: distribution unlimited.

Fit ill-defined E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data

These two points do not well define a hyperbolic fit.

Page 15: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

15 DISTRIBUTION A. Approved for public release: distribution unlimited.

Proposed Measurement Paths E

Σ

Navy MEMS Data

Army MEM data

EDF-11 Threshold Data Threshold FIt

.5 mil flyer

1 mil flyer

2 mil flyer

3 mil flyer

Each flyer thickness defines a path through HJ space.

Page 16: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

16 DISTRIBUTION A. Approved for public release: distribution unlimited.

EDF-11 HJ Parameterization • Electric gun will be used to make

EDF-11 sensitivity measurements. • Conduct threshold testing at

several flyer thicknesses and a representative flyer dimension

• Limited number of previous measurements at EFI relevant length scales, but spot size dependent.

Need to have Hugh James Initiation data at MEMS scales

Page 17: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

17 DISTRIBUTION A. Approved for public release: distribution unlimited.

Upcoming • Finish detonator experiments and fit distribution

function

• Multiple threshold test series of EDF-11 in a MEMS relevant Hugh James Space – 0.5,1,2, and 3 mil thick Kapton

• Transfer lead output test series – PDV measurements of lead output

• Compile Navy and Army data, map into generated James space and estimate system reliabilities

Page 18: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

18 DISTRIBUTION A. Approved for public release: distribution unlimited.

Conclusions • New explosive trains require new methods of analysis.

• These new methods can better aid intelligent design.

• We are utilizing a new method to quantify the reliability of

small explosive trains with a reasonable number of asset firings.

• Both and the Navy and Army are committed to ensuring that MEMS fuzing achieves the highest degrees of reliability possible.

Page 19: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

19 DISTRIBUTION A. Approved for public release: distribution unlimited.

Acknowledgments Section: Thanks to the Joint Fuze Technology Program (JFTP) for funding this work.

Thanks to Chadd May and Lawrence Livermore National Labs (LLNL) for the loan of the

electric gun.

Thanks to Eric Welle and the Air Force Research Laboratory for Hugh James implementation support.

Thanks to those who have helped work on the project:

ARDEC

Roger Cornell Daniel Stec

Charlie Robinson Brian Fuchs

NSWC IHEODTD Daniel Lanterman G. Shane Rolfe Jason Brindle Daniel Pines

Page 20: DoD MEMS Fuze Reliability Evaluation...DoD MEMS Fuze Reliability Evaluation 59th Annual NDIA Fuze Conference, Charleston, SC Thursday, May 5th 2016, Open Session IVA, 10:20 Taylor

DISTRIBUTION A. Approved for public release: distribution unlimited.

Questions?