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AD818416

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FROMDistribution authorized to U.S. Gov't.agencies and their contractors; CriticalTechnology; 15 AUG 1967. Other requestsshall be referred to Air Force MaterialsLab., Wright-Patterson AFB, OH 45433.

AUTHORITY

AFML ltr 7 May 1970

THIS PAGE IS UNCLASSIFIED

-- I I I

August 15, 1967

DMIC Memorandum 224

REVIEW-OF ALLOYS AND FABRICATING METHODS

USED FOR TACTICAL MISSILE NMOTOR CASES

DEFENSE. METALS INFORMATION CENTER,

BATTELLE, MEMORIAL INSTITUTE

COLUMBUS, ,(YHII -43201 -

j 0p,,r- cnttlsand eat'r ~ ~ ~ ~ tis document i r, e~ t-)s1~ S;' ontra n O!tx- nsit-tal to 'ekfl Z'

~ 0~-yWith prior arrovl o

The Defense Metals- Information Center was established at- Battelle Memorial Institute atthe request of-the Office--of-the -Director of -Defense Research, andoEngineering to provide Govern-ment-contractors and their suppliers-technical assistance'and inforrnation on titanium, beryllium,,magnesium, aluminum, high-strength-steels, . refractory metals, high-strength alloys for -high-temperature, seivice, and, corrosion- and oxidation-resistant coatings. Its functions, under thedirection of-the Office of the-Director of Defense-Research and Engineering, are as follows:

1. To collect, store, and disseminate technical information on the currentstatus of--research and development of the above materials.

2. To supplement established Service activities in providing technical ad-visory services'to producers, melters, and fabricators of the abovematerials, and to-designera andfabricators of military equipment con-taining, these- materials.

3. To assist the Government-agencies and their contractors in developingtechnical data required- for preparation of specifications for the abovematerials.

4. On-assignment,. to conduct surveys, or laboratory researchinvestiga-tions, mainly of a short-range nature,, as required, toascertain causesof troubles, encoimtexed'by fabricators, or to fill minor gaps in estab-lished research programs.

Contract No. AF 33(615)-;3408

1V J. Director

-Notices

When Government drawings, specifications,, or other -data-are usedfor-&nypurpose other tviqn inconnection With.a definitely related Government procurement operation, the United'States Governmn-,tthereby incurs norespqnibility-nor any obligation whatsoever; and-the fact that the Government-mayi aveformnulated, furnished, cr, i. a;. -,my *uppiiedthe said drawings, spcificatiois, or-other-data, isnot-to'be regarded.by irnpication-or otherwise as-in any,manner licensing the holder or any other perzon

or corporation, or conveying any-rights or permission.to manufacture, use, or sellany patented inven-tion- that may in,any way be related thereto.

-Qualifiedrequesters-may obtain copies of this report from the Defense JDodumentation Center (DDC),Cameron Station, Bldg. 5, 5010 Duke Street, Alexandria, Virginia, 22314. The-distribution of this re-,port -is limited becauqse r the report'contains-technology -identifiable, with-items on the strategic -embargolists excluded from: export.or re-expbrt under'U. S. Export Control Act of- 1949 (63 STAT. 7), as amended(50 U.S.C. App. 2020-2031), as implemented by AFR 400-10.

Copiesof.,this report shouldhnat-be rdturned tothe Research and- Technology Division, Wright-:U .ssa A:.r Fri-ce B~ase, Ohiv, unless return fis-requiredby security considerations, contractual ob-

ligations) or notice-on a spocific document.

II

TABLE OF CONTENT S ag

SUMMARY . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . I

USE OF MARAGING STEELS FOR MISSILE CASES . . . . . . . . . . . I

OTHER ALLOY STEELS FOR MISSILE MOTOR CASES . . . . . . . . . . 2

BIBLIOGRAPHY . . . . . . . . . . . . . . . . . . . . 3

'1Ii

SAPPENDIX A. DATA ON MISSILES AND MISSILE MOTOR CASES .. .. .. A-1

SSolid-Propellant Mi1ssiles . . . . . . . . . . . . . . A-1

Other Tactical Missil s . . . . . . . . . . . . . . . A-9

I

REVIEW OF ALLOYS AND FABRICATING METHODS USED FOR TACTICAL-MISSILE MOTOR CASES

J. E. Campbell*

SUMARYMinimum weight of the inert components of

This memorandum discusses alloys used for mo- missiles is desired from the standpoint of trans-tor cases for 21 solid-propellant and four liquid- portation, the amount of ordnance that can bepropellant missiles of the tactical type. Early carried by a single aircraft, and the potentialsolid-propellant-missile motor cases were usually range of the missile. As a consequence, most motorfabricated of AISI 4130 steel and were often not cases designed for more recent missiles are beingheat treated. Since then, there has been a trend made of high-strength materials such as D6ac steel,toward uz of Ml- +--O, -1 oy steels - pri- maraging steels , solution-treated-and-aged Ti-6AI-marily AISI 4340 and D6ac - a.id the cases have been 4V alloy, and glass-fiber composites. (Glass-fiberheat treated to 200,000 to 250,000-psi tensile cases are not considered in this memorandum.) Thestrength. In recent developments, maraging steels only production missile motor cas2 for which the

r are being considered for the motor cases and other Ti-6AI-4V alloy is used is the second stage of thecomponents of new missiles because of the ease of Minuteman.* Its use is limited because of costshear spinning, heat treating, etc. The trend to- factors. Aluminum alloys are used for severalward higher strer.th motor-case materials is reason- missile motor cases such as the Lance (2024-T6able so long as tha fabricators can demonstrate cap- alloy) and the Zuni (7075-T6 alloy). Motor casesabilities for "inspecing out" flaws that approach in most of the other tactical missiles are fabrica-critical size and that are larger than critical ted from alloy steels.size. Fabrication procedures also have advancedfrom the roll-and-weld technique to deep-drawing and USE OF MARAGING STEELS FOR MISSILE CASESshear-spinning techniques that provide definite ad-vantages for production of missile cases. Maraging steels have been used for large

boosters of 120- and 260-inch diameter in severalAlloy steels and aluminum alloys have been programs involving successful test firings with

used for liquid-propellant motor cases of "pre- solid propellants.(l,2) * Maraging steels werepackaged propellant" design. Use of titanium alloys selected for the large boosters because of theirfor production motor cases is limited to cases for ease of forming in the annealed condition, thethe second stage of the Minuteman missile. relatively simple aging treatment for developing

comparatively high strength levels in thick sections,INTRODUCTION good weldability under controlled conditions,

Afeasibility of localized aging of weld areas, andA number of inquiries have been received by good toughness.

the Defense Metals Information Center for infoima-tion on alloys and fabricating methods for motor These advantages also apply to the manufacturecases for tactical missiles. This memorandum sum- of smaller tactical-missile motor cases. The work-marizes available information on missile motor cases hardening coefficient of the alloy is lower thanthat are in either development or production phases. that of other alloy steels. Thus, deep drawing andData on alloys used for motor cases of specific tac- shear spinning are feasible processes for formingtical missiles, obtained through a DMIC survey of cylindrical shapes of the maraging steels. Ringthe missile project offices, are given in the forgings or rolled-and-welded plate preforms may beAppendix. For the reader's convenience, basic used as blanks for shear spinning cylindrical sec-missile data from the March 6, 1967 issue of Avia- tions. Cold working actually adds to the strengthtion Week and Space Technology are included. Be- level that can be achieved on aging. However, thecause improvements are frequently made in design, cold-working effect is eliminated in the heat-material selection, fabrication procedures, missile affe-ted zones at welds. Aging at 900 F to developperformance, etc., the status of any of these motor maximum tensile properties causes little if anycases may change over a period of time. For ex- distortion from warping and almost negliqible changeample, the trend toward the use of higher strength in dimensions from the age-hardening reaction.alloys for solid-propellant rocket motor cases is Also, there is no decarburization. Fracture tough-evident in the changes which have already been made ness of the aged alloy at a given strength levelin the choice of materials, is higher than that of other alloy steels. A

partial list of applications of maraging steels forThe early missile motor cases were often made missile motor cases is presented in Table I.

of AISI 4130 steel rolled and welded or flow turnedfrom a forged ring. In some instances, the cases Because of the advantages noted above, therewere not heat treated after fabrication. However, is a tendency for designers to select the 300 gradebecause of requirements for lower inert-weight and (280,000 to 290,000-psi yield strength, or higherthe resulting increased service stresses, heat for the cold-worked alloy) of maraging steel. Iftreatments were established for AISI 4130 steel the 300 grade is selected, the fabricator shouldmotor cases and motor cases of other low-alloy demonstrate a capability for detecting flaws nearsteels. Development of the early Polaris motor critical size by production nondestructive-testingcases indicated a need for improved nondestructive techniques. Accurate techniques for estimatingtesting procedures, improved welding procedures, and critical flaw sizes in thin shells at certaina better understanding of fracture toughness re-quirements in high-strength pressure vessels. Cer-tain improvements have been made in these areas over *Titanium alloys have been used in experimentalthe past 9 or 10 years. fabrication of solid-propellant motor cases, such*Associate Fellow, Mechanical Metallurgy Division, as Pershing and Alcor.Battelle Memorial Institute, Columbus, Ohio. **References are given on page 3.

2

TABLE 1. SELECTED APPLICATIONS OF MARAGING STEELS FOR MISSILE MOTOR CASES(a)

Case Dimensions

Wall Yield TensileName of Diemp Lengthg Thickness, Quantity Alloy Strength, Strengtht

Missile Contractor in. In. in. Produced Grade Forming Process ksi ksi Status

Condor Bostrom 300 Shear spin Development

Condor Thiokol, RMD 17 250 Shear spin .. .. Development

Lance Coast Metal Craft 15.28 Bell-shaped thrust 300+ 250 Roll and weld (EM), 250 -- Production

chamber contoured to size

Minuteman Allison 24 48 0.120 -- 300 Shear spin 285 -- Development

lit Stage (subscale)

Minuteman Curtiss- 65 .. .. 1 250/ Shear spin 225/ -- Development

1st Stage Wright Corp. 300 270

Pershing Intercontinental 39.82 78.55 -- 1 250 Shear spin .. .. Development

Pershing Curtiss- 40 .... 4 .... ..

2nd Stage Wright Corp.

Redeye Marquardt 2.5 26 -- 1 300 Roll and weld ringp 270 -- Developmentshear spin

Redeye Missile Engrg 2.5 24 -- several ? Roll extrusior. -- -- Development

Tow General Electric 2.75 24 -- 9 300 Shear spin 280 -- Development

Tow Norris- 5.75 5 0.220 100+ 250 Deep draw -- 310- Development

Thermador 2.5 17 0.070 100+ 300 Deep draw -- 320 Development

(a) Coleman, A. A., "High-Strength Maraglng Steels for Tactical Missile Rocket Motors", Report R-4384, Rocketdyne Division,

North American Aviation, Inc., Solid Rocket Divisiont McGregor, Texas (July 13, 1966).

strength levels and proof pressures are not well OTHER ALLOY STEELS FOR MISSILE MOTOR CASESestablished, since methods for plane-stress fracture-toughness testing have not been standardized,. How- Following the trend for devel6ping missileever, prototype cases containing small intentional motor cases with higher strengths than could beflaws produced by electrical-dischaige machining obtained with AISI 4130 steel, steels having highermay be subjected to proof tests. If the nondestruc- carbon contents and higher hardenabilities havetive testing methods used are capable of detecting been used in more recent missile designs. Modifica-all flaws near critical size and larger,* the tions of AISI 4340 steel or D6ac steel are beingmaterial selection would appear to be satisfactory. used in many current motor cases for tactical mis-

If not, a lower strength, tougher alloy should be siles. Cases of these alloy steels are usuallyevaluated in the same way. fabricated by the roll-and-weld techniue or by

shear spinning. Forged end closures are thenVacuum-remelted alloy steels tend to be tough- welded onto the cylindrical sections.

er than corresponding air-melted alloy steels,which also may be true of the maraging steels. To develop high strength levels in theseHowever, if air-melted maraging steels have ade- steels, heat treating, which consists of austenitiz-quate toughness for a given application, the higher ing, quenching, and tempering, is required. Incost of vacuum-remelted alloys of the ome grades some instances, hot-salt-bath quenching has beenwould not be warranted, even though they may be used to minimize quenching distortion on heat treat-tougher. Information is being souqht on this ques- ing. Special fixturing is usually necessary totion for a future Defense Metals Information Cen- minimize distortion of thin-wall cases during theter report. For a specific motor-case design, air- high-temperature austenitizing treatment. Specialmelted m~raging steel certainly may be used for furnace atmospheres also are required to preventprototype cases. These cases then can be proof or minimize decarburization. These special process-tested with and without intentional flaws, as sug- ing procedures have been developed successfully togested above, to arrive at an apparent critical meet the requirements of high-strength mlsslieflaw size. It is suggested that this technique motor cases produced from low-alloy steels. D6acbe used to verify critical-crack-size estimates alloy steel has been fabricatad for the cylindricaleven after the state of the art has advanced to section of the Shillelagh missile by ausformingthe point where reasonably accurate critical-crack- techniques, which result in high strength and goodsize estimates can be made. This practice will aid toughness. The end closures are welded to thein developing confidence in th? NDT methods and zylindrical sections by electron-beam welding.sh)uld lead to fewer failures on proof testing. Ifit is found that the air-melted alloys have ade- The low-alloy martensitic steels can be ob-quate toughness, the extra expense of the vacuum- tained for substantially lower cost than othermelted alloys could be avoided, more highly alloyed steels such as the maraging

or the HP-9Ni-4Co steels. However, for certainapplications, the maraging steels may have specific

*A critical-size flaw is the smallest size that advantages.

will initiate fracture of a given material at agiven strength level at a specified proof stress Use of the HP-9Ni-4Co steels for motor-casefor a definite wall thickness, orientation, and applications has been limited to large cases,

service temperature. specifically those 120 inches in diameter (Tech-nology Week, p. 28, June 13, 1966). Plate of the

3HP-9Ni-4Co-25 grade may be heat treated to 190,000- Perlmutter, I., and DePierre, V., "Steels forpsi yield strength before forming. After heat treat- Solid-Propellant Rocket-Motor Cases", Technical

_ ting, it is rolled into a cylindrical shape, welded Report AFML-TR-64-356 (January, 1965).at the longitudinal joint, and then roll extruded tofinal dimensions f:r the cylindrical portion of the Raymer, j. M., "Metastable Austenitic Forming ofcase. This procedure results in a motor case of High Strength Pressure Vessels", AV Corporation,high strength and good toughness, requiring no heat Report ML-TDR-64-174, Contract AF 33(657)-7955treatment after fabrication. DMIC is not aware of (July, 1964).any productiond fabrication of smaller motor casesfor tactical missiles using HP-N-4Co-25 steel by "Design, Development and Fabrication of Ultra Highthis technique. Strength Solid Propellant Rocket Motor Cases",

Curtiss-Wright Corporation, Final Technical ReportExperimental missile motor cases have been RPL-TDR-64-114, Contract AF 04(611)-9064 (August,

produced by cryoforming Type 301 stainless steel. 1964).In this process, a preform of the case is producedby welding together cylindrical and conical shapes Fowler, E. L., "Cold Forming of Maraging Stoels",of annealed Type 301 stainless steel. The preform Machinery (April, 1965).is submerged in and pressurized with liquid nitrogen(-320 F). A simp]e cylindrical die controls the Gerberich, W. W., Williams, A. J., Martin, D. F.,outside diameter limit. During pressurizing, the and Heise, R. E., "Ausform Fabrication and Propershell is stretched about 12 percent, resulting in ties of High Strength Alloy Steel", Philcoconsiderable cold working and strengthening. The Publication No. U-2355 (November 23, 1963).weld areas are strengthened about the same as theparent metal. The strength levels achieved are com- Frank, R. G., and Zimmerman, W. F., Materials forpetitive with the strength levels achieved in mar- Rockets and Missiles The MacMillan Company, Newaging steels. York, New York (1959).

REFERENCES

(1) "260-In.-Dia. Motor Feasibility DemonstrationProgram", Aerojet-General Corporation,Sacramenti, California, Final Program SummaryReport, ;ASA CR 72127, Contract NAS 3-6284(April 8, 1966).

(2) "Desig., Fabrication, and Hydrotesting of a120-Inch Diameter Pressure Vessel Using 18Percent Ni Maraging Steel", Lockheed PropulsionCompany, Redlands, California, Final ReportRPL-TDR-64-82, Contract AF 04(611)-8525(October 2, 1964).

BIBLIOGRAPHY

Ernestus, A. W., "Process Development for InternalRoll Extrusion of Large Rocket Motor Cases", NTWMissile Engineering, Inc., Report AFML-TR-66-114,

Contract AF 33(657)-9754 (April, 1966).

Melville, A., "Metallurgical Evaluation of 18 PercentNickel Maraging Steel (300 KSI Strength Level)",Thiokol Chemical Corporation; paper presented atThird Maraging Steel Project Review, Report RTD-TDR-63-4048 (November, 1963).ISernka, R. P, "Spin Forge Processing of the 300 KSIGrade Maraging 18% Ni Steel", Lear-Sigler, Inc.;IL paper presented at the Third Maraging Steel Project;r Review, Report RD-TDR-63-4048 (November, 1963).

V

i"

I APPENDIX A

DATA ON MISSILES AND MISSILE MOTOR CASES

1

.1

Ct

APPENDIX A

DATA ON MISSILES AND MISSILE MOTOR CASES

Solid-Propellant Missiles

Motor Case Data (continued)ASROC

Case Length, in. 19.355Designation RUR-SA Case Diameter, in. 6.259 + 0.002Service USN Wall Thickness, in. 0.081 + 0.004Mission Antisubmarine Motor Length with Nozzle, in. 28.43Prime Contractor or Technical HoneywellDirector Mechanical Properties of Case Material

Missile Data ed Strength, psi 75,000Tensile Strength, psi 95,000

Overall Length, ft 15 Eiongaion, percent 10 minimumMaximum Body Diameter, in. 12 (span 2.5 ft)Total Launch Weight, lb 940 ReferencesNumber of Stages (Motors) 1Motor Designation -- Technical Services Section, Missile Support Branch,Motor Contractor Naval Propellant Hill Air Force Base, Utah

PlantPropellant Type Solid extruded

double base HAWK

Motor-Case DataDesignation MIM-23A

Case Material Steel Service ArmyFabricating Methods Rolled and welded Mission Surface to airCase Length, in. 56.3 Prime ontractor or Technical RaytheonCase Diameter, in. -- DirectorWall Thickness, in. 0.200Proof or Burst Pressure, psig -- Missile Data

Mechanical Properties of Case Mate -ial Overall Length, ft 16Maximum Body Diameter, in. 14

Yield Strength, psi 160,000 minimum Total Launch Weight, lb 1300Tensile Strength, psi -- Number of Stages (Motors) 1 (dual thrust)Elongation, percent 8.9 minimum Motor Designation M-22E8

Motor Contractor AerojetReferences Propellant Type Polyurethane +

Missile Propulsion Branch, Department of the Navy; Maximum Range, nautical miles 22

Aviation Week (March 6, 1967).Motor-Case Data

FALCON Case Material AISI 4132 steelFabricating Methods Roll and weldCase Length, in. 85

Designation AIM 4G Case Diameter, in. --Service USAF Wall Thickness, in. 0.093 to 0.105Mission Air to airPrime Contractor or Technical Hughes Mechanical Properties of Case MaterialDirector

Yield Strength, psi 170,000 to 175,000Missile Data Tensile Strength, psi 180,000 to 200,000

Elongation, percent 10-12Overall Length, ft 6.77Maximum Body Diameter, in. 6.64 ReferencesTotal Launch Weight, lb 145Number of Stages (Motors) 1 Hawk Project Manager's Office, Redstone Arsenal;Motor Designation M-46 Aviation Week (March 6, 1967)Motor Contractor ThiokolPropellant Polysulfide, Al +

NH4CIO4 MINUTEMAN II

Motor Case DataDesignation LGM-30F

Case Material AISI 4130 (IIL-S- Service USAF18729) steel, Mission Surface to surfaceannealed Prime Contractor or Technical AFSC/BSD, Boeing

Fabricating Methods Drawn and machined Directorfor attachments

A-2

Missile Data Motor-Case Data

Overall Length, ft 60 Case Material D6ac steelMaximum Body Diameter, in. 65.5 Fabricating Methods Hydro-spun cylindri-

r c Total Launch Weight, lb -- cal sections withNumrber of Stages (Motors) 3 welded end clo-

Stage I Stage II Stage III sureMotor Designation TU-122 XSR-19- M-57 First Stage Second Stage

AJI Case Length, in. 102.6 96.0Motor Contractor Thiokol Aerojet Hercules Case Diameter, in. 40 40Propellant Type Solid Solid Solid Wall Thickness, in. 0.090 0.068

com- cam- double

posite pasite base Mechanical Properties of Case MaterialMaximum Range, nautical 7000 +

miles Yield Strength, psi --Tensile Strength, psi 195,000 to 220,000

Motor-Case Data Elongation, percent 6

Case Material D6ac Ti-6A1- Glass Referencessteel 4V fiber

com- Pershing Project Manager's Office, Redstone Arsenal;posite Aviation Week (March 6, 1967)

i °Fabricating Methods Shear Shear Fiber

form form, wrap-STA,(a) ping PHOENIXi : weld,

C Lgre-ageCase Length, in.(b) 222.6/ 108.7/ 61.8/ Designation AIM-54A

257.9 122.5 69.5 Service USNCase Diameter, in. - . .. .. Mission Air to airWall Thickness, in. - . .. .. Prime Contractor or Technical Hughes

DirectorMechanical Properties of Case Material

Missile DataYield Strength, psi .. .. ..Tensile Strength, psi .. .. .. Overall Length, ft 14Elongation, percent 10 8 -- Maximum Body Diameter, In. 15

Total Launch Weight, lb 1000References Nurber of Stages (Motors) 1

Motor Designation MK 47 Mod 0Headquarters Baflistic Systems Division (AFSC), Motor Contractor NAA/RocketdyneNorton Air Force Base, California; Aviation Week Propellant Type Solid composite(March 6, 1967)

Motor-Case Data16 (a) Solution treat and partial age. Complete aging

follows the welding. Case Material Ladish D6ac steel(b) Skirt to skirt/forward dome to nozzle flange. Fabricating Methods Machined forgings

spinningCase Length, in. 41.4

PERSHING Case Diameter, in. 14.7Wall Thickness, in. 0.043

Designation MGM-31A Case Weight, lb 32.89Service ArmyMission Battlefield support Mechanical Properties of Case MaterialPrime Contractor or Technical Martin/OrlandoDirector Yield Strength, psi

Tensile Strength, psi 200,000 to 225,000Missile Data Elongation, percent

Reduction in Area, percent --

Overall Length, ft 30.61Maximum Body Diameter, in. 40.15 ReferencesTotal Launch Weight, lb 10,252Num)er of Stages (Motors) 2 Missile Propulsion Branch, Department of the Navy;Motor Designation TX-174 (XM-105), Rocketdyne, Solid Rocket Division, McGregor, Texas;

TX-175 (XN-106) Aviation Week (March 6, 1967)Motor Contractor ThiokolPropellant Type PBAA composite

(hydrocrabon,aluminum, and REDEYE

NH4 CI04)Maximum Range, nautical miles 400 Designation FIM-43A

A-3

General Data (continued) Motor-Case Data (continued)

Service Army Case Length, in. 170 (motor lengthMission Surface to air 195 in.)Prime Contractor or Technical General Dynamics/ Case Diameter, in. 31Director Ponpioa Wall Thickness, in. 0.109

Missile Data Fins are AZ91-T6 magnesium alloy castings. Jetvanes are glass fiber-phenolic resin composite with

Overall Length, ft 4 molybdenum (AMS 780r) leading edges.Maximum Body Diameter, in. 2.77Total Launch Weight, lb 18 Mechanical Properties of Case MaterialNumber of Stages (Motors) 2Motor Designation XN-99 Yield Strength, psi 135,000Motor Contractor Atlantic Research Tensile Strength, psi 165,000 to 195,000Propellant Type Arcite Elongation, percent 6 to 7 (MIL-H-

6875)Motor-Case Data References

Case Material H-11 steelFabricating Methods Deep draw(a) U. S. Army Missile Command, Redstone Arsenal,

(Fabricator is Alabama; Aviation Week (March 6, 1967)NorrisIndustries)

Case Length, in. 24 SHILLELAGHCase Diameter, in. --

Wall Thickness, in. 0.020Designation )NGM-51B

Mechanical Properties of Case Material Service ArmyMission Battlefield support

Yield Strength, psi 190,000 Prime Contractor or Technical Philco AeronutronicTensile Strength, psi -- DirectorElongation, pecent 4.5

Missile DataReferences

Overall Length, ft 3.8Redeye Project Office, Redstone Arsenal; Aviation Maximum Body Diameter, in. 5.95Week (March 6, 1967) Total Launch Weight, lb 61.54

Number of Stages (Motors) 1 + control(a) The motor case has been fabricated in small reaction jets

qumntities by the roll-extrusion process of Motor Designation --NTW Missile Engineering Company. Motor cases Motor Contractor Picatinny Arsenal,of both H-11 steel and maraging steel have been Amoco Chemicalsfabricated by this method. Solid (N5 and

LFT3A)Maximum Range, nautical miles 10

SERGEANT Motor-Case Data

Designation MGM-29A Case Material Type D6ac alloyService Army steelMission Battlefield support Fabricating Me hods Tubing, cut toPrime Contractor or Technical Sperry Utah Company length, EB welded,Director and finish

machinedmissie Data Case Length, in. 16.29

Case Diameter, in. 5.95Overall Length, ft 33.5 Wall Thickness, in. 0.040 (shoit chambeMaximum Body Di&neter, in. 31 0,047 (long chambe)Total Launch Weight, lb 10,000 Proof Pressure, psig 2200 (30 secondsNumber of Stages (Motors) 1 minimum) for shortMotor Designation XM-100 chamber and 2000Motor Contractor -- (5 seconds minimum)Propellant Type Polysulfide for long chamber

ammoniumperchlorate Mechanical Properties of Case Material

Maximum Range, nautical miles 75 Yield Strength, psi 185,000 minimum

Motor-Case Data Tensile Strength, psi 210,000 minimum

(210,000 to 230,000Case Material A7SI 4130 steel Elongation, percent in 2 in. 5 minimum (trans-Fbbricating Methods Rol. ad weld verse)

fabrication Hardness RC 42 to RC 48

_A-4

Mechanical Properties of Case Material (continued) Missile Data

Heat Treatment Preheat to 1150 F, Overall Length, ft 9.5austenitize at Maximum Body uiameter, in. 51650 F for 30 Total Launch Weight, lb 195minutes, salt Nu.mber of Stages (Motors) 1quench to 400 F Motor Designation Mk 36 Mod 2 and 5for 5 minutes, Motor Contractor NAA/Rocketdynetemper at 1025 F Propellant Type Solid-compositetwice for 2 + 2 polybutadienehours carboxyl termina-

tionReferences Maximum Range, nautical miles 10

Project Manager, Shillelagh, Redstone Arsenal; Motor-Case Data"Electron Beam Spurs Shillelagh-Making", Steel,9:p. 58 (March 21, 1966). Case Material AISI 4130 steel

Fabricating Methods Deep drawn andwelded

- SHRIKE Case Length, in. 70.9

Case Diameter, in. 5.01Wall Thickness, in. 0.060 i3 0.003

Designation AGM-45A Case Weight, lb 24Service USN, USAF Burst Pressure, psig 3500

Mission Air to surfacePrime Contractor or Technical Naval Ordnance Mechanical Properties of Case Material

Director Test Station,Texas Instruments, Yield Strength, psi --Sperry-Farragut Tensile Strength, psi 160,000 minimum

Elongation, percent 6 minimum

Missile Data Rfrne

Overall Length, ft 12Ma-imum Body Diameter, in. 8 Missile Propulsion Branch, Department of the NavyTc al Launch Weight, lb 400 Rocketdyne, Solid Rocket Division, McGregor, Texas

I Numbrr of Stages (Mctors) 1 Aviation Week (March 6, 1967)Motor Designation Mk39 Mod 3Motor Contractor NAA/Rocketdyne,

Aerojet SPARROW III-6BPropellant Type Solid composite

Motor Case Data Designation AIM-7EService USN, USAF

Case Material AISI 4130 steel Mission Air to airFabricating Methods Rolled and welded Prime Contractor or Technical Raytheon

or deep drawn DirectorCase Length, in. 48.2Case Diameter, in. 8.0 Missile Data-Wall Thickness, in. 0.052 to 0.060Case Weight, lb 22.6 Overall Length, ft 12

Maximum Body Diameter, in. 8Mechanical Properties of Case Material Total Launch Weight, lb 400

Number of Stages (Motors) 1[ Yield Strength, psi 170,000 Motor Designation Mk 38 Mod 2Tensile Stre:ngth, psi 185,000 to 205,000 Motor Contractor NAA/Rocketdyne,Elongation, percent 8 minimum Aerojet

Propellant Type Solid compositeReferences Maximum Range, nautical miles 12

Missile Propulsion Branch, Department of the Navy; Motor-Case DataRocketdyne, Solid Rocket Division, McGregor, TexastAviation Week (March 6, 1967) Case Material AISI 4130 steel

__Fabricating Methods Rolleri and weldedor deep drawn

SIDEWINDER Case Length, In. 48.2Case Diameter, in. 8.0'Wall Thickness, in. 0.052 to 0.060

Designation AIM-9C and 9D Case Weight, lb 22.6Service USNMission Air to air Mechanical Properties of Case MaterialPrime Contractor or Technical Naval Ordnance

1 •Director Test Station, Yield Strength, psi 170,COOPhilco, Raytheon Tenrile Strength, psi 185,000 to 205,000

Elongation, percent 8 minimum

A-5

References Missile Data (continued)

Missile Propulsion Branch, Department of the Navy; Motor Designation Mk 30 Mod 1, Mk 30

Rocketdyne, Solid Rocket Division, McGregor, Texas, Mod 2

Aviation Week (March 6, 1967) Motor Contractor Atlantic ResearchPropellant Type Solid (both stages)Maximum Range, nautical miles 30+ (terrier

replacement)STANDARD MISSILE, TYPE I-MR

(M R for medium range) Motor-Case Data

Case Material AISI 4130 ond 4140steel

Designation YRIM-66A Fabricating Methods Slip-rolled cylin-

Service USN ders, forged ends,

Mission Surface to air weldedPrime Contractor or Technical General Dynamics/ Booster Sustainer

Director Pomona Case Length, 4n. 131.26 55.84Case Diameter, in. -- 13.5

Missile Data Wall Thickness, in. 0.087 to 0.063 to0.099 0.068

Overall Length, ft 15Maximum Body Diameter, in. 13.5 Mechanical Properties of Case Materia]Total Launch Weight, lb 1406Number of Stages (Motors) 1 (dual thrust) Yield Strength, psi 75,000 75,000

Motor Designation Mk 27 Mod 2 Tensile Strength, psi 95,000 95,000Motor Contractor Aerojet-General Elongation, percent 12 12Propellant Type Solid composite

dual burning References

Maximum Range, nautical miles 10 + (tartarreplacement) Missile Propulsion Branch, Department of the Navy;

Surface Misstle Systems Project Office; DepartmentMotor-Case Data of the Navy; Aviation Week (March 6, 1967).

Case Material AMS 6429 steel(4340) SUBROC

Fabricating Methods Rolled and weldedor shear formed,forged ends Designation UUM-44A

Case Length, in. 90 Service USNCase Diameter, in. 13.5 Mission AntisubmarineWall Thickness, in. 0.110 to 0.115 Prime Contractor or Technical Goodyear Aerospace

Director

Mechanical Properties of Case Material

Missile DataYield Strength, psi 190,000Tensile Strength, psi 210,000 Overall Length, ft 21Elongation, percent 12 Maximum Body Diameter, in. 21

Total Launch Weight, lb 4000References Number of Stages (Motors) 1

Motor Designation TE-260G (Mk 45Missile Propulsion Branch, Department of the Navyj Mod o)Surface Missile Systems Project Office, Department Motor Contractor Thiokolof the Navy; Aviation Week (March 6, 1967) Propellant Type Solid composite

polyurethaneMotor-Case Data

pluehn

STANDARD MISSILE, TYPE I-ER(ER for extended range) Case Material AISI 4132 steel

Fabricating Methods --

Case Length, in. 137Case Diameter, in. --

Designation YRIM-67A Wall Thickness, in. 0.219Service USNMission Surface to air Mechanical Properties of Case MaterialPrime Contractor or Technical General Dynamics/Director Pomona Yield Strength, psi --

Tensile Strength, psi --

Missile Data Elongation, percent --

Overall Length, ft 27 ReferencesMaximum Body Diameter, in. 18Total Launch Weight, lb 3000 Missile Propulsion Branch, Department of the Navy;Number of Stages (Motors) 2 Aviation Week (March 6, 1967)

A-6

Motor-Case DataN TALOS

Case Material AISI 4135 steelDesignation RIM-8E Fabricating Methods Shear-formed cyl-Service USN inder, forged endMission Surface to air closuresPrime Contractor or Technical Bendix Case Lengthc in. 81.8

F r- Director Case Diameter, in. 13.5Wall Thickness, in. 0.105 to 0.115

L Missile Data Proof or Burst Pressure, psig 2560 (burst)

Overall Length, ft 32 Mechanical Properties of Case MaterialMaximum Body Diameter, in. 36Total Launch Weight, lb 7700 Yield Strength, psi 75,000Number of Stages (Motor) 2 Tensile Strength, psi 95,000SBooster Sustainer Elongation, percent 12Motor Designation Mk 11 TRamjet)

Mod 5 Referencest Motor Contractor Naval Pro- Bendix,pellant McDonnell Missile Propulsion Branch, Department of the Navy;

L- Plant Aviation Week (March 6, 1967)[ Propellant Type Solid double Ramjetbase JP-5

1 Maximum Range, nautical miles 65+ TERRIER (H-)VMotor-Case Data \~M

Designation RIM-2ECase Material AISI 4130, -- Service USN

4140 steel Mission Surface to airFabricating Methods Stamped and Prime Contractor or Technical General Dynamics/

drawn or Director PomonaU welded- Case Length, in. 101.5 101 Missile Data

Case Diameter, in. -- --

Wall Thickness, in. 0.150 to -" Overall Length, ft 270.165 Maximum Body Diameter, in. 18

Total Launch Weight, lb 3000Mechanical Properties of Case Material N o f ages (Mto 2F[Number of Stages (Motors) 2

Booster SustainerYield Strength, psi 160,000 -- Motor Designation MK 12 Mod 1 Mk 30 Mod 2T minimum Motor Contractor Naval Pro- AtlanticTensile Strngth, pi 185,000-- pellant Research

minimum PlantElongation, percent 7 minimum -- Propellant Type Solid Solid

(polyrinalReferences chloride +

NH4CI04)Missile Propulsion Branch, Department of the Navy; Maximum Range, nautical miles -- 20+Aviation Week (March 6, 1967)

___Motor-Case Data

TARTAR Case Material AISI 4130, AISI 4130,

4140 steel 4135 steelj Fabricating Methods Slip-rolled Slip-rolledDesination RIM-24B cylinders, cylinders,Service USN welded, welded,Mission Surface to air forged end forged endPrime Contractor or Technical Generai Dyn.,nlcs/ closures closuresDirector Pomona Case Length, in. 131.26 55.84

Case Diameter, in. -- 13.5Missile Data Wall Thickness, in. 0.087 to 0.063 to

0.099 0.068Overall Length, ft 15Maximum Body Diameter, in. 13.5 Mechanical Properties of Case MaterialTotal Launch Weight, lb 1425

4 Number of Stages (Motors) I (dual thrust) Yield Strength, psi 75,000 75,000Motor Designation Mk 27 Mod 2 Tensile Strength, psi 95,000 95,000Motor Contractor Aerojet Elongation, percent 12 12Propellant Type Dual-burning solid

composite ReferencesMaximum Rang3, nautical miles 10+

Missile Propulsion Branch, Department of the Navy;V Aviation Week (March 6, 1967)

A-7Motor-Case Data (continued)

TOWVectoring

Designation XMGM-71A Booster Sustainer MotorService Army Fabricating Rolled, --

Mission Battlefield support Methods seamPrime Contractor or Technical Hughes weldedDirector Motor Length, in. 203.1 -- 48.2

Motor Diameter, in. 43.1 -- 29.4Missile Data Wall Thickness, in. --...

Overall Length, ft Mechanical Properties of Case MaterialMaximum Body Diameter, in.Total Launch Weight, lb -- Yield Strength, psi 200,000Number of Stages (Motors) 2 chambers Tensile Strength, psi 250,000Motor Designation K-41 Elongation, percent 6Motor Contractor Hercules (cases

fabricated at ReferencesNorris Thermador)

Propellant Type Solid Information Office, Department of the Army, RedstoneArsenal; Aviation Week (March 6, 1967)

Motor-Case Data

Case Material 18Ni (259) l8Ni (300)Fabricating Methods Deep drawn Deep drawnCase Length, in. 5.0 17Case Diameter, in. 5.75 2.5 Designation Mk 41Wall Thickness, in. 0.220 0.070 Service USN

Mission Air to surfaceMechanical Properties of Case Material Prime Contractor or Technical Naval Ordnance Test

Director Station, NavalYield Strength, psi .... Ammunition DepotTensile Strength, psi 250,000 310,000Elongation, percent --- Missile Data

References Overall Length, ft 9.2Maximum Body Diameter, in. 5.125

"High Strength Maraging Steels for Tactical Missile Total Launch Weight, lb 107Rocket Motors", Rocketdyne Report R-4384; Aviation Number of Stages (Motors) 1Week (March 6, 1967) Motor Designation --

Mctor Contractor --Propellant Type Solid standard X-8

ZEUS (DM 15X-2) (extruded)

Motor-Case DataDesignation XLIM-49AService Army Case Material 7075-T6 aluminumMission Surface to air alloyPrime Contractor or Technical Bell Telephone Fabricating Methods Deep drawnDirector Laboratories, Case Length, in. 61.698

Western Electric Case Diameter, in. 5Wall Thickness, in. 0.138

Missile Data

Mechanical Properties of Case MaterialOverall Length, ft 50Maximum Body Diameter, in. -- Yield Strength, psi 66,000Total Launch Weight, lb -- Tensile Strength, psi 77,000Number of Stages (Motors) 3 Elongation, percent 7 minimum

VectoringBooster Sustainer Motor References

Motor Designation TX-135 TX-235-6 TX-239Motor Contractor Thiokol Thiokol Thiokol Missile Propulsion Branch, Department of the Navy;Propellant Type Hydro- Hydro- Hydro- Aviation Week (March 6, 1967)

carbon, carbon, carbon,Al + Al + Al +NH4ClO 4 NH4ClO4 NH4CIO4

Maximum Range, .. .. 100nautical miles

Motor-Case Data

Case Material AISI 4340 ---steel

A-8

Liquid-Propellant Missiles

Motor-Case Data

BULLPUP A and B Case Material Maraging steel

Fabricating Methods Shear spinningDesignation AGM-12B, AGM-12C Case Length, in. --

Service USN Case Diameter, in. 17Mission Air to surface Wall Thickness, in. --Prime Contractor or Technical Maxson Electronics,Director Martin Company Mechanical Properties of Case Material

Missile Data Yield Strength, psi --

12B 12C Tensile Strength, psi --Overall Length, ft 11 13.5 Elongation, percent --Maximum Body Diameter, in. 12 18Total Launch Weight, lb 575 1800 ReferencesNumber of Stages (Motors) 1 1Motor Designation I.R5-RM 4 L162-RM-2 Thiokol, Reaction Motors Division; Aviation WeekMotor Contractor Thiokol/ Thiokol/ (March 6, 1967)

RMD RMDPropellant Type Prepackgqd Prepackgd: -=-- "liqutdaJ liudtal LANCE

Maximum Range, 6 9 LCnautical miles

Designation XMGM-52AMotor.Cate Data Service Army

Mission Battlefield supportCase Material AISI 4130 2014-T6 Al Prime Contractor or Technical Ling-Temco-Vought

I ___ steel DirectorFabricating Methods Stamped, --

drawn, Missile Datawelded

Case Length, in. 32.09 61 Overall Length, ft 20Case Diameter, in. 12 17.3 Maximum Body Diameter, in. 22Wall Thickness, in. 0.069 "" Total Launch Weight, lb 3262

Number of Stages (Motors) Boost and sustainMechanical Properties of Case Material from one system

Motor Designation --Yield Strength, psi 75,000 Motor Contractor RocketdyneTensile Strength, psi 95,000 -- Propellant Type Liquid (IRFNA & UDMH)Elongation, percent 12 --Reduction in Area, percent .. Motor-Case Data

References Case Material 2014-T6

Fabricating Methods Shear formed. Missile Propulsion Branch, Department of the Navy; cylindrical shells,

__ Aviation Week (March 6, 1967) forged end clos-_______ures, joined by(a) MAF-I (mixed amine fuc!) and inhibited red electron-beam

fuming nitric acid. welding

____Case Length, in. 111.5Case Diameter, in. 22

CONDOR Wall Thickness, in.0.336 + 0.005

Designation AGM-53A Mechanical Properties of Case MaterialService USNMission Air to surface Yield Strength, psi 59,000 transversePrime Contractor or Technical North American 60,000 longitudinalDirector Aviation, Inc. Tensile Strength, psi 67,000 transverse,

(Columbus 68,000 longitudinalDivision) Elongation, percent 6

Missile DataReferences

Overall Length, ft -- Lance Project Office, Redstone Arsenal; AviationMaximum Body Diameter, in. -- Week (March 6, 1967); "Lance Material Selection",Total Launch Weight, lb -- Report MBE-63-2, Redstone Arsenal (October 1, 1963).Motor Designation --

Motor Contractor Thiokol, ReactionMotors Division

Propellant Type Prepackaged liquid

A-9

Other Tactical Missiles

No information beyond that already published Entacin Aviation Week & Space Technology, March 6. 1967. Geniewas available because of security restrictions or Honest Johnbecause final decisions had not been reached on Lacrossecase material for the following missiles which pre- Little Johnsumably have metal cases: Mauler (nMS 6434 cylinder, AISI 4130 end

closures)Advanced Surface Missile System MAUChaparral (Surface to air version of Nike-Hercules

Sidewinder) Sam-DSRJALM

SS-10SS-11

ITetonRamjet and turbojet missiles are outside the

scope of this report.

ii

rt

Y LIST OF DMIC MEMORANDA ISSUEDDEFENSE METALS INFORMATION CENTER

Battelle Memorial InstituteColumbus, Ohio 43201

Copies of the memoranda listed below may be obtained, while the supply lasts, from DMIC at no costby Government agencies, and by Government contractors, subcontractors, and their suppliers. Qualifiedrequestors may also order copies of these memoranda from the Defense Documentation Center (DDC), CameronStation, Building 5, 5010 Duke Street, Alexandria, Virginia 22314. A complete listing of previouslyissued DMIC memoranda may be obtained by writing DMIC.

DMICNumber Title

203 Recent Information on Long-Time Creep Data for Columbium Alloys, April 26, 1965 (AD 464715)204 Sum0dry of the Tenth M-oting of the Rfacto, ryCr~npoite Working Group. May 5. 1965 (AD 465260)205 Corrosion Protection of Magnesium and Magnesium Alloys, June 1, 1965 (AD 469906)206 Beryllium Ingot Sheet, Aigust 10, 1965 (AD 470551)207 Mechanical and Physical Properties of Invar and Invar-Type Alloys, August 31, 1965 (AD 474255)208 New Developments in Welding Steels With Yield Strengths Greater Than 150,000 psi, September 28,

1965 (AD 473484)209 Materials for Spare-Power Liquid Metals Service, October 5, 1965 (AD 473754)210 Metallurgy and Properties of Thoria-Strengthened Nickel, October 1, 1965 (AD 474854)211 Recent Developments in Welding Thick Titanium Plate, November 24, 1965 (AD 477403)212 Summary of the Eleventh Meeting of the Refractory Composites Working Group, April 1, 1966213 Review of Dimensional Instability in Metals, June 23, 1966 (AD 481620)

214 Surrace Welding in the Space Environment, June 9, 1966215 Titanium - 1966 (Lectures Given at a Norair Symposium, March 28-29, 1966), September 1, 1966216 Weldability of High-Strength Aluminum Alloys, August 22, 1966217 A Survey of the Feasibility of an Analytical Approach to Die Design in Closed-Die Forging, June 1,

1966218 Corrosion of Titanium, September 1, 1966219 Vacuum-Degassed Steels From the Consumer's Viewpoint, September 15, 1966I 220 The 9Ni-4Co Steels, October 1, 1966 (AD 801977)221 First National Symposium of The Center for High-Energy-Rate Forming, November 1, 1966222 Summary of the Twelfth Meeting of the Refractory Composites Working Group, April 1, 1967223 Designations of Alloys for the Aerospace Industry, April 12, 1967

I

A-9

Other Tactical Missiles

No information beyond that already published Entacin Aviation Week & Space Technology, March 6, 1967, Geniewas available because of security restrictions or Honest Johnbeae= final decisions had' noL been reached on Lacrosse

case material for the following missiles which pre- Little Johnsumably have metal cases: Mauler (MS 6434 cylinder, AISI 4130 end

closures)Advanced Surface Missile System MAUChaparral (Surface to air version of Nike-HerculesSidewinder) Sam-D

SRAISS-l0SS-llTeton

Ramjet and turbojet missiles are outside thescope of this report.

UnclassifiedSecurity Classification

DOCUMENT CONTROL DATA -R&D(Security claasification of title body of abstract and Indexing annotattnn must be ant.red hen the overall report is classllid)

I. ORIGINATING ACTIVITY (Corporate author) 12A. RCPORT SECUnfTY r I A-1 2-!,A

Defense Metals Information Center UnclassifiedBattelle Memorial Institute 2b"GROUP505 King Avenue, Columbus, Ohio 43201

3. REPORT TITLEReview of Alloys and Fabricating Methods Used for Tactical-Missile Motor 3ases

4. DESCRIPTIVE NOTES (Type of report and Inclusive data&)

DMIC Memorandum5. AUTHOR(S) (Last name, firat name. Initial)

Campbell, J. E.

~ ~, ~7. TOTAL NO. OF PAG ES 7b. NO. OF REFS

'August 1, 1967 12 2Ga. CONTRACT OR GRANT NO. 9e. ORIGINATOR'S REPORT NUMBER(S)AF 33(615)-3408b. PROJECT NO. DMIC Memorandum 224

.b. OTHR RPORT NO(S) (Any othernumbere thatmay be assigned

d.

10. AVAILABILITY/LIMITATION NOTICES Copies of this memorandum may be obtained, while the

supply lasts, from DMIC at no cost by Government agencies, contractors, subcon-tractors, and their suppliers. Qualified requestors may also obtain copies of thilmemorandum from the Defense Documentation Center (DDC), Alexandria, Virginia 22314,

II. SUPPLEMENTARY NOTES 12. SPONSORING MILITARY ACTIVITYUnited States Air Force

Research and Technology DivisionWright-Patterson Air Force Base, Ohio

13. ABSTRACT

This memorandum discusses alloys used for motor cases fox 21 solid-propellant and four liquid-propellant missiles of the tactical type. The factorsinvolved in the choice of higher strength steels for solid-propellant motor casesaxe discussed, with particular emphasis on the problem of fracture toughness.Trends in the selection of alloys for missile motor cases are pointed out. Anappendix provides detailed information on materials and fabrication methods usedfor selected missiles.

DD I AN 1473 UnclassifiedSecurity Classification

UnclassifiedSecurity Classification14. LINK A LIN ..... LINK C

KEY WORDS RO-L -WTR ..... 1

Tactical Missiles 'j Motor Case Materials

Maraging SteelsFracture ToughnessNon-Destructive Testing

tI

INSTRUCTIONS

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