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TRANSCRIPT
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CLEARINGHOUSE fqr Federal Scientific & Techniral Information Springfield Va. 22151
■
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U. S. NAVAL AMUUNITION DEPOT Crane, Indiana 47522
RDTR No. 121 Jul 1968
DiPROVKD ILLUMINATING FURE
Bornard E. Doude
This report was reviowed for edequacy and technical acouraoy by J. D. Wise. Chemical Engineer.
Released
B. H. CALKINS, Manager Concept Division Reseerch and Development
RDTR No. 121
TABU GT OONTBITS Page
ABSTRACT 11
PURPOSE 1
BACXOROUND 2
BXPBRBBNTAL 3
DISCUSSION 7
CONCLUSIONS 11
ACKNOKUSDQBIENTS 12
RKFERENCES H
APPENDIX I 13
APPINDIX II 1*
RDTR No. 121
ABSTRACT
1. Data are presented to show that a less expensive magnesium
can be used to make an Illuminating flare candle which generates
at least as much light as conventional compositions. The compo-
sition utilizes an improved binder.
11
•
ROTR No. 121
IMPROVED ILLUMINATING FLARE
A Feasibility Study
PURPOSE
1. The purpose of this report is to describe the completion
of a feasibility study which demonstrated that a less expensive
magnesim could be used to make an illuninating flare candle with
equal to or better perfomance than the present ?flc 24 Mod 4 Aircraft
Parachute Flare candle by replacing the hinder with an improved
binder system.
■ -
RDTR No. 121
BAOKQROOND
1. About one year ago, the Thiokol Chemloal Corporation,
under oontraot to the Air Force and the Navy, prooeeded with
the development of an advanced oaetable flan ocapoei LeA«
That work is reported in reference (l). The binder used in
preparing the oaatable formulation was a mixture of
oarboxyl terminated polyester resin and em epoxy resin
catalysed with xron linoleate. The test results from the
oast work were most encouraging. It appeared that this
binder system had certain advantages ever resins which had
been evaluated in the past. Specifically, when this binder
system was used to oast the composition, it was observed that
the luminous efficiency of the composition was at least
equal to the luminous efficiency of compositions oast with
other resin systems. The favorable results from this work
suggested that the binder system ould be used to advantage
in a press candle as well as in cast candles. It is with
this background that an effort was started to determine
whether or not it was feasible to use the allegedly Improved
binder system in a pressed candle formulation.
WTR No. 121
EXPERIMEKTAL
1. Flare Description.
a. The candles prepared for tests were similar to candles
in the Mk 24 Mod 4 Aircraft Parachute Flare. Additional details
relating to that flare can be found in reference (2). Generally,
the composition is consolidated into a paper tube with an inside
diameter of 4.2S inches and with about one quarter inch wall
thickness. The length of conposition in the candle is about 16
inches.
2. Candle Fabrication Process.
a. Magnesiun and sodiun nitrate have been used extensively
for making illuminating flare compositirms. Their granular size
is often varied to cause changes in the burning rate of the
composition. Also the ratio of these ingredients causes changes
in the burning rate as well as the efficiency (candle-seconds per
gran). A third ingredient is added to the system. That in-
gredient, the binder, is normally a plastic in mononeric form
which later can be polymerized to bond the composition to itself
and to its container. In compositions prepared for pressing,
the binder contents normally range from 3 to 5% by weight.
b. Usually, the first step is to preblend the binder
and magnesiun in a mixer. The mixer often used is a Simpson
Mix Müller as sold by the National Engineering Company, Chicago,
Illinois, The preblending process desensitizes the magnesiun,
RETR No. 121
reduces the dust hazard, and inhibits surface oxidation of the
magnesium particles.
c. The binder materials each are liquid in their
procured form. The epcocy resin, polyester resin, and iron
linoleate are preblended prior to addition to the magneslun.
d. The sodiun nitrate is later aided to the preblend.
This mass is then mixed until a homogeneous blend is obtained.
\yhen the binder content is about 4 to 4,5 percent, the composition
has the appearance of being slightly damp. The next step in
making a flare consists of taking weighed increments of the
composition, placing them in the candle case, and then con-
solidating that composition under high pressure. A sixty ton
press is noimally ased to consolidate the composition in a Mk 24
tube. This results in a consolidation pressure of near 8400 nsi.
Since the binder utilized in these experiments requires an
elevated temperature cure, the candles are next placed in a
curing room whose temperature is maintained at approximately
150oF, The candle composition is effectively cured at this
temperature in about 48 to 60 hours.
3. Materials.
a. The source of the ingredients used in making the il-
luninating composition is given in Appendix I. Because this
study deals primarily with the binders used, the following
additional infoimation is included.
RDTR No, 121
i
b. The formula for the epcocy-polyester system, consists
of about 77.51 Fomrei F17-80 polyester resin, 19.5t, ERLD-OSOO
epcocy resin, and 3.0t iron linoleate.
c. The epoxy resins ERLD-OSOO and KRL-0510 are both
products of Union Carbide Corporation manufactured under
U. S. Patent 2,951,825. The idealized structure is:
CH. V lo^W^'V*
^ /
Y o
CH,-CH-cV, NJ / *
O
The two products are triglycidyl derivatives of para-anino phenol.
ERLD-0500 is the reaction product of para-amino pheiol and
epichlorohydrin in the presence of caustic. Like all such products,
ERLD-0500 contains some polymeric material with pendant hydroxyl
groups. Carmercially produced, KRLD-05{)0 has a viscosity of 2000
to 5000 cps at roan temperature. The presence of hydroxyl groups in
the material produces seme catalytic effects and hence shortens
potlife. To overcome this, the ERLD-0500 is molecularily
distilled to produce a product known as HRL-0510 which is
essentially the monomeric triglicidyl derivative of para-amino
ROTH No. 121
phenol. It is a pale straw-colored liquid with a viscosity of
400 to 700 cps*.
d. Fomrez F17-80 is a carboxyl terminated polyester
produced by Witco Chemical Company. Its emperical formulation and
typical analysis is:
Emperical Formulation
C1.6 H2.55 01.0
Typical Analysis
3.0 72.0 0.04 40,000
Hydroxyl No. Acid No. Moisture, % Viscosity, cps 9 2S*C
e. Source data and information about the remaining in- gredients such as magnesium, sodium nitrate, and iron linoleate may be found in Appendix I.
4. Test Procedure. a. All of the candles were burned in an inverted position,
that is, with the flame pointed downward. The units were either tested in the photometric tunnel or at the MAPI site. Units tested in the photometric tunnel are given a test number prefixed with the letter T. The test number for units tested at MAPI are prefixed with the letter M. For those persons who are not familiar with the MAPI site, additional details may be found on page 11 of reference (3). The units tested in the photometric tunnel were tested using the procedure described in reference (4) for Mk 24 Aircraft Parachute Flares.
•From Union Carbide Product Data sheets.
RDTR No. 121
DISCUSSION
1. Candle Performance,
a. The luninous efficiency of an illuninating candle is a
measure of its perfornance. That value is normally presented in
units of candle-seconds per gram. Table I, which is a tabulation
of the properties of the flare tested, shows clearly that units
containing binder fonnula #2 are more efficient than units
containing binder formula #1 or #3. Generally, standard M 24
Flares when tested in the tunnel exhibit a luninous efficiency
of 48 to 50,000 candle-seconds per gram. This was the value
expected for the units in Table I identified with binder formula
#3. However, because the units burned too rapidly, a minor
decrease in the efficiency is observed. Another binder svstem,
identified as binder formula #1 in Table I, is an epoxy foimula
which gives efficiencies comparable to the Mk 24 Flare, The
most remarkable result of this work is the luninous efficiency
data for the epoxy »polyester resin system identi fied as binder
fonnula #2, That series of units shows efficiencies considerably
greater than 50,000 candle-seconds per gram. It is noteworthy
that these levels of performance weu achieved with a low cost
magnesiun, (Note added in proof: See Table IX in Appendix II for more conclusive data.)
2. Economics.
a. It has already been mentioned that the magnesiun used
to achieve these high levels of luninous efficiency is a material
which costs much less than the material now being used in the
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ROTR No. 121
standard Mk 24 Flare. For ethical reasons, exact material
prices for magnesium and binders which were used to make the
study of economics will not be provided. It can be stated,
however, that the polyester resin Formrez F17-80 and the epcncy
resins ERLD-0S00 are both substantially more costly than the
Laminae resin presently used in the Mk 24 Flare. Likewise, the
30/50 atomized magnesiun used in the Mk 24 Flare is also
considerably more expensive than is magnesiin identified by
grades PMC-20, RMC-60, or RMO+SO. When the analysis is made,
it is found that the low magnesiun cost far offsets the
higher priced binder. The net result is that if mapnesiun is
used wherein the magnesium content is 53*R1C-20 and 5% RMC-60,
and after allowing for the increased binder cost, the savings
are estimated between $.80 and $1.00 per candle. The savings
would be substantially larger if PMC-+30 were utilized as the
magnesiun in the new formula. Appendix II contains tables
which show the performance of candles using other magnesiuns.
3. Elevated Temperature Cure
a. The epoxy-polyester formula consisting of Formrez
F17-80 and cpoocy HRLD-OSOO as utilized in this feasibility
study requires an elevated temperature cure. It was mentioned
previously that about 48 to 60 hours at 150oF for a candle of
this size (15 lbs.) is adequate. For some producers, especially
those who ire not presently equipped with large heated storage
rooms, such an elevated temperature cure requirement would
present no problem. If the cure schedule as described is
RTTR No. 121
unacceptable, it is suggested that this binder could he converted
to a rocm temperature cure. Such action would, of course,
introduce a tendency toward a higher exotherm during poly-
merization as well as shorter potlife. Thus, corresponding
processing adjustments would have to be made,
b. Tables III and IV of Appendix JI show a series of
candles which were tested when the candles were at varying age.
These series were made and tested becau»c it had been suspected
that the candles were not curing nroperly. As can be seen by
the study,the luninous efficiency of both of these series increases
as the age of the candle increases. This characteristic is not
one which is nomally cxnected. It may result, however, from
the fact that the epoxy resins utilized were approximately nine
months old and had pre-polymeri zed considerably during their
storage period. Such a condition does not notmally occur when a
fresh supply of rosin (less than three months old) is used.
10
RDTR No. 121
OONCLUSIONS
1. It has been demonstrated that a Mk 24 size candle can
be pressed using illuninating composition which contains a
low-cost magnesium without sacrifice to the luminous efficiency
of the unit. As a matter of fact, it has been showed that it
is possible to increase the luminous efficiency while using the
low-cost magnesiun when the present polyester resin is replaced
with the epoxy-polyester binder foimila described in this
report. It was estimated further that by change to the improved
binder fomula and to the low-cost magnesiun, the illuninating
candle cost can be reduced in the neighborhood of $1.00 ner
unit. With this report, the feasibility study is considered to
be complete. Further develojtnent and evaluation is recmnended
as the next immediate step.
11
ROTR No. 121
ACKNOWLBDQKimiTS
1. The study was supported by LT. Ilargaret A. Frederick,
Naval Air Systems Comnand, Code AIR-350F, Washington, D. C.
The oooposltlon was mixed and pressed under the direction of
Mr. Gary Norris, RAD Department, NAD Crane.
RgFBRBNCES
1. IdoDermott, J. 11., Advanced Castable Flare IHumlnant, RDTR 99, U. S. Naval Anmunition Depot, Crane, Indiana, August 1967.
2. fyroteohnic, Screening, and Dye-Marking Devices, NAVNKPS OP 2213, Naval Ordnance Systems Command, Washington, D. C. 20360, first revision, 1 October 1965, with 16 changes through 1 February 1968.
3. Douda, B. B., 25 Million Candle Cast Flare, Diameter, and Binder Study, RDTR No. 105, Volumes I and II, ü. S. Naval Ammunition Depot, Crane, Indiana, January 1966.
4. Flare, Aircraft Parachute Mk 24 Nods, NAVORD OS 8766H with Amendment 1 of 4 January 1968.
12
RDTR No. 121
APPMDP I
List of Materials
Tonnz FIT-60 Carboxjl tamlnated polyester resin
Nitoo Chemical Co. 75 B. Walker Drive Chicago, Illinois 60601 Phone: 312-346-2960 Attn: Mr. Hannas on
■poxy Resin BRL-0510 Thiokol Chenioal Corp. Speoifioation T1IS-RM-1003
Union Carbide Corp. 230 North Michigan Ave. Chicago, Illinois 60601 Phone: Area 312-346-3300
■poxy Resin BR1D-0500 Thiokol Chemical Corp. Speoifioation TWS-RH-64
Iron Linoleate Thiokol Chemical Corp. Speoifioation TNS-RM-1002
Union Carbide Corp. Plastics Division 2330 Victory Parkway Cincinnatti, Ohio 45206 Phone: 513-272-0202 Attn: Miss Oldiges
Harshaw Chemical Co. 1945 Bast 97th St. Cleveland, Ohio 44106 Phone: 216-721-8300 Attn: Mr. Bill Riese
Sodium Nitrate Davies Nitrate Co. P. 0. Box 306 Metuehen, N. J. 08840 Attn: Mr. A. Nheaton
Magnesium Other, than RMC grades
Magnesium, all grades whose number is prefixed with the initials RMC
Valley Metallurgical Processing Co. Bssex, Conn. 06426
ReadB Manufacturing Corp. Lakehurst, N. J.
Dow Bpoxy Resin DBR 321 Dow Bpoxy Hardner DBH 31
Dow Chemical Co. 3909 North Meridian St. Indianapolis, Indiana Phone: 317-926-3441 Attn: Mr. Joe O'Brien
46208
13
APPENDIX II
Contains Tables II through IX
14
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S«curity CI««iiflc>tion
DOCUMENT CONTROL DATA • R&D ff—MWr cl—«W««W«n «I mi», holy ml «telnc« and Indaitn« annoMNdn aw« >j »n»«f< »«mi j>» «glgM gpjg I« efc»»tfl«0
I O^IOINATINO ACTIVITY rCcqMMM author;
0. 8. Naval Aaaunltlon D»pet 0r«M. Indlwa
2«. HIPORT •CCUniTV C LAttiriCATIOM
Dnolasslfivd 16 OBOUP
I «tPOUT TITLt
Jmprovd niuBlnatliig Flare
4. OUCNWIVI NOTIS (Typ» ol npart and Meknlra *l*a;
Coipletlon of faaalbllity study » AUTNORffl) AMI nan», flral n«M. InlUml)
Douda, Barnard K. • M»ORT BATt
July 1967 Ta- TOTAL NO. OF r «SCi
• a. CONTRACT OR aRANT NO
A35-632-082/323-1/F008-17-02 k RROJtCT NO. Rork Unit #4
22 IRTJJ
RDTR No. 121
lb. OTHKR RfRORT NOfS; M ny offiar numöara Aal may 6« aaalinad Ala rmporO
I«. AVAILAtlUITY/LIMtTATION NOTICES
Distribution of this doouaent is unlimited.
II SUP 5TM It. SPONSORING MILITARY ACTIVITY
Naval Air Systens Ccomand Code 350F Rashington. D. 0. 20360
II. ABSTRACT
x Data are presented to shoe that a less expensive magnesium oan be used to Bales an illuminating flare candle «hioh generates at least as much light as oonventional ooapositions. The oomposition utilises an improved binder. —
DD FORM 1 JAN «4 1473 o<oi-a«?-Moo
23 UNCUSSITUD Security Ctassification
PNOUSg ITIMD ty CUsi Security CUiiiflcation
14. KEY WOUOS
LINK ■ LINKC
1. niuBinating flar*s 8. Flares 3. «poxy resins 4. Polyester resins 5. Resins 6. Binders 7. Uk 24 AP Flare 8. Luminous intensity 9. Bernard B. Douda
INSTRUCTIONS
\. ORIGINATING ACTIVITY: Enter Ihe name and addrc«* of the contractor, aubcontractor, grantee, Department of De- fenae activity or other organitation (corporal» author) laaulng the report.
2a. REPORT SECUHTY CLASSIFICATION: Enter the over- all aecurlty claaalflcallon of the report. Indicate whether "Reatricted Data" la Included, Marking la to be In accord- ance with appropriate security regulation«.
2b. GROUP: Automatic downgrading la apectflad in Dot) Di- rective 5200.10 and Armed Force* Induatrlat Manual. Enter the group number. Alao, when applicable, ahow that uptional marking« have been uaed for Group 3 and Group 4 aa author- ised.
3. REPORT TITLE: Enter the complete report title In ell capital latter«. Titles In all caaea should be unclaaalfled. If a meaningful title cannot be «elected without claaalfica- tion, show title classification In all capitals in parenthesis Immediately following the title.
4. DESCRIPTIVE NOTES: It appropriate, enter the type of report, e.g., interim, progrea«, «ummary, annual, or final. Give the Indualva datea when a apedfic reporting period la covered.
5. AUTHOR(S): Enter Ihe nane(s) of authoK«) aa ahown on or in the report. Enter laat name, firat name, middle initial. If military, ahow rank and branch of aervlce. The name of the principal author ia an absolute minimum requirement.
6. REPORT DATE: Enter the date of the report ea day, month, year, or month, year If more than one date appeara on the report, uae date of publication.
7a. TOTAL NUMBER OF PAGES: The total page count ahould follow normal pagination procedures, I.e., enter the number of pagea containing information.
7b. NUMBER OF REFERENCES Enter the total number of reference« cited in the report.
8a. CONTRACT OR GRANT NUMBER: If appropriate, enter the applicable number of the contract or grant under which the report waa written.
8b, 8c, a 8d. PROJECT NUMBER: Enter the eppropriete military department Identification, auch aa project number, aubproject number, aystam number«, teak number, etc
9a. ORIGINATOR'S REPORT NUMBER(S): Enter the offi- cial report number by which the document will be identified and controlled by the originating activity. Thia number muat ba unique to thla report. 9b. OTHER REPORT NUMBERS): If the report haa been aaalgned any other report numbers (either by the originator or by the sponsor), alao enter thla numbeKs).
10. AVAILABILITY/LIMITATION NOTICES: Enter eny lim- itation« on further dissemlnstion of Ihe report, other than thoae
imposed by aecurity claaalfication, uaing standard ststements such as:
(1) "Qualified requester» may obtain coplea of thia report from DDC"
(2) "Foreign announcement and dissemination of thla report by DDC ia not authorized."
(3) "U. S. Government agenciea may obtain copies of this report directly fmm DDC. Other qualified DDC users shall request through
(4) "U. S. military agenciea may obtain coplea of this report directly from DDC Other qualified users shell request through
(S) "All distribution of this report is controlled. Qual- ified DDC users shall request through
If the report has been furnished to the Office of Technical Services, Depsrtmen: of Commerce, for sale to the public, indi- cate this fact and enter the price, if knowa
11. SUPPLEMENTARY NOTES: Uae for additional aiplana- tory notes.
12. SPONSORING MILITARY ACTIVITY: Enter the name of the dapartmental project office or laboratory sponsoring (p»y ing lor) the reaearch and development. Include address.
13 ABSTRACT: Enter an abatract giving a brief and factual summary of the document indicative of Ihe report, even though it may slso appear elsewhere in the body of Ihe technical re- port. If additional apace ia required, a continuation sheet shall be sttsched.
It is highly desirable that Ihe abstract of classified reports be unclassified. Eech paragraph of the abalracl shall end with en indication of Ihe military aecurity classification of the in- formation in the paragraph, represented aa ITS), rs). (C). or (V).
There is no limitation on the length i' 'he abstract. How- ever, the suggested length is from ISO to 225 words.
14. KEY WORDS'. Key words ere lechnicslly mesningful terma or short phrases that rharacteriae a report and may be used aa inde» entries for cataloging the report. Key words must be selected so thst no security classification is required. Identi- fiers, such as equipment model designation, trade name, military project code name, geographic location, may be used aa key words but will be followed by an indication of technical con- test. The assignment of links, roles, and weights is optional.
UNCUSSZPIBO Security Claisification