excellence in energetics - thomasnetcdn.thomasnet.com/ccp/10036979/170295.pdf · excellence in...

Since 1961 See last page for contact information.

August 2013

Excellence in Energetics

Quality Management System‐ISO 9001:2008

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Stresau Laboratory: Where energetic performance is defined. What do an automotive airbag and an artillery shell have in common? The answer lies at Stresau Laboratory where energetic performance is defined. There is, in these devices and others like them, no margin for failure. Each must function when fired, never when it should not. Stresau Laboratory has satisfied that need since 1961 and continues this technology in new arenas today. Richard Stresau's research on explosive propagation phenomena allowed the US to develop and field ordnance faster than the competition. And the competition in 1944 was deadly. In 1961 he opened his own laboratory in the north woods of Wisconsin. The US ordnance industry beat a path to it with two questions: Does this energetic device work? How many destructive tests will prove it? Stresau Laboratory provided -- and still provides -- the answers. It refined the technology and expanded the scope until nearly every fuze explosive train in the US Army arsenal had passed through Stresau test and evaluation. Stresau Laboratory’s experience reflects both its longevity (adapting the NATO 120mm round to US production in the ‘70s) and its continued relevance (JPF supplier, MEMS test-bed today) in both development and production of explosive components. Stresau Laboratory’s evaluation expertise has been used in many programs by every service and a variety of industries. The lists on pages four and five name some of the military programs, which represent every service, and a variety of delivery modes. These range from medium caliber to missiles and include propulsion and warhead energetics; military and civilian contracts. Stresau continues to expand the energetic envelope conducting development work to load primary explosives directly on MEMS devices. Likewise, while its focus remains energetics, it applies this expertise across a breadth of activity for military and commercial customers, production and development contracts. Stresau is organized to respond to this diversity with three operating areas:

• Development, Test and Evaluation • Manufacturing • Hazardous Materials Testing

The distinct capabilities of these areas are highlighted in the following pages. It affords a perspective on the range of capabilities Stresau offers and examples of the programs to which they have been applied. Each of these areas is staffed with its own experts. However, it is important to note that Stresau encourages cross utilization of expertise and resources. This keeps prices down and maximizes the resources which Stresau can bring to bear on specific challenges.

Stresau Laboratory, Inc. of 20Profile of Experience & Capability

Manufacturing Stresau manufactures energetic components for the world’s most demanding customers in quantities from dozens to millions. Some of these items, such as the M442 Fuze components and Patriot Explosive Train Assembly, were items in which Stresau participated in development and continues to produce. Other components, such as medium caliber detonators and leads, Stresau supplies because customers have come to rely on this best value vendor’s low cost, high quality, dependable schedules and customer service. That customer service might be best described by a phrase we hear from our customers. “These guys return my phone calls.”

Medium Caliber Lead and Detonator: High Quantity Stresau manufactures both the stab detonator and lead, which in various configurations initiate the warhead in several of the medium caliber rounds used by the U.S. Army. More than 7 million of these rounds have supplied such critical systems as the Bradley Fighting Vehicles, Apache helicopters and the A-10 Warthog. Stresau has delivered consistent quality on schedule and at the least cost procurement to its customer. Stresau proposed an innovative test and lot acceptance procedure that, approved by both the prime contractor and the US Army, further refined quality, reduced the price and offered the customer a more flexible delivery schedule.

M6 Special Electric Blasting Cap: High Quantity Customer: U.S. Army, OSC Rock Island Stresau’s M6 Special Electric Blasting Cap (NSN: 1375-013-16-1229) provides the Army and Marine Corps new quality and performance in a blasting cap that has, over its years of service, been specified for many applications. Stresau’s assembly meets new performance requirements for both the Blasting Cap itself and the protective packaging that enhances safety in static and RF (radio frequency) saturated environments.

Custom M6 Blasting Cap: Very Low Quantity Customer: Various US Service Laboratories and Sub-Contractors In response to IED defeat efforts Stresau provides M6’s modified to meet customer specific variants. Typically these have reduced output or exposed components to facilitate research.

M7 Non-Electric Blasting Cap: High Quantity Customer: U.S. Navy In addition to its field use the M7 Blasting Cap, like the M6, is used to initiate Composition C-4 in test applications and in qualifying Composition C-4 production lots. Stresau does not manufacture the safety fuze, such as M700 Safety Fuze, that is used to ignite the blasting cap. Military Blasting Caps, which also include the M4 Blasting Cap, are distinguished by an output capable of initiating Composition C-4.

M442 Fuze Energetics: Medium Quantity The Expulsion Charge and Two Second Delay operate the final stage in the U.S. Army’s M-257 Standoff Illuminating Flare. Stresau manufactures both units in this complex system. Stresau also LAPs (Load, Assemble and Pack) the fuze for this program under separate contract. This is not only a technically demanding program but also one that requires schedule and contractual details to be coordinated between two levels of customers for Stresau.

M6 Blasting Cap


Micro-Miniature Electric Detonators Stresau is improving its capability for the scalable production of micro-miniature electric detonators such as the M100 or the PA537. A unique automatic welding machine, with digitized vision, can “see” the ultra-fine bridgewire and weld it to exacting tolerances. Stresau’s ability to operate short and medium run production, and its willingness to custom load variations of existing designs, lets the customer fine-tune performance at prices comparable to the standard item in large volume. This keeps customer’s costs down during development, full production and every phase in between.

Patriot Explosive Train Assembly: Low Quantity Patriot Missile may be the U.S. weapon system with the most widely known name thanks to its high profile performance in the Gulf War. Originally an anti-aircraft weapon its anti-missile configuration was developed just in time for its use in the Gulf war. The inventory was very low when Gulf hostilities began and Stresau’s ETA was among the components on the critical path of production. Stresau met the delivery demands with 100% performance then, and since.

Electric Detonators: Various Quantities, Critical Applications Stresau builds both Stab Detonators and Electric Detonators. It provides several customer such standards as the Mk71 and T20E1 detonators for such programs as Harpoon, Hawk, Brimstone and commercial applications. Stresau builds PA536 and PA537 and custom M100 detonators with characteristics such as function time, durability and output tuned to the customers specific requirements. Automated Bridgewire Welding equipment expanded this capability in 2001.

Stresau Laboratory Parts and Programs, a partial list: P/N MK Task Program 1211001 Initiator Air Bag 2120002 MK21 Cup Assy Standard 5619088 EX37 Arming Device MK50 5816999 Mk50 Lanyard Start Mk50 6106216 CCU89 20 Sec Delay 9220893 PA501 Lead Dragon 9245691 M100 Detonator 9282648 PA511 Lead Stinger 9298733 M442 Fuze M257 9332277 Gas Generator M257 9355704 Pic 75mm 2595552 Mk46 Explosive Train Mk46 3016-01 Actuator SFAFM 3485A Cable Cutter 6012203A Detonator Tip B1 Bomber 6133119a1 Mk216 Bursting Chg. Mk216 777073-10 Det Cord Assy TMD 777253-10 Explosive Bolt TMD 817065A M257 Delay Block M257 817066A M257 Expulsion Chg. M257 11834324 M759 2 Pc. Stab Det M758/59 12526626 M830 Booster 120mm 12527143 M123 Electric Primer 120mm 065-4619 Mk47 Impulse Cart 088-5629 MK46 Igniter MK46 12525016 M125 Primer 120mm 158AS100 FZU50 Bomb Fuze FZU50 84719-2-3 SAF Booster Maverick


Development, Test & Evaluation Stresau Laboratory, Inc., is known as the fuze explosive train specialist. The reputation comes from more than fifty years of explosive train safety and reliability evaluation. Richard Stresau's research on explosive propagation phenomena allowed the US to develop and field ordnance faster than the competition. And the competition in 1944 was deadly. In 1961 he opened his own laboratory in the north woods of Wisconsin. The US ordnance industry has beat a path to it ever since. Developed by the Navy in the 1950’s and refined by Stresau in the 1960's, these evaluation protocols soon became international standards and continue to be so today. Testimony to this is found in the Army inventory where nearly every fuze explosive train has passed through Stresau test and evaluation. Stresau’s statistical models and carefully controlled penalty function testing can validate designs in the most cost-effective manner. The methods are based on assigning a penalty to the interface being evaluated. Penalties frequently used are barrier thickness, gap, strength of donor output (Varidrive) and sensitivity of the explosive donor (Varicomp). A quantitative system using common statistical methods is used to compare the interface under penalty with the design interface. This offers predictions of high rates of reliability or safety on the basis of a few test trials. Stresau helps evaluate the safety and reliability of many U.S. Army fuzes/S&As. A large quantity of Air Force and Navy fuzing/safing devices are also evaluated at Stresau. The following are details for a few sample activities.

MEMS Fuzing and Initiation Customer: Army TACOM-ARDEC Micro Electro Mechanical fuzes promise big performance at microscopic size for a variety of applications in weapons systems. The jump from electro mechanical to an energetic initiation is a challenge brought to Stresau by both the Government and prime contractors.

Qualification of the New MOFA Explosive Train Customer: Army TACOM-ARDEC Under this contract Stresau participated in the qualification testing for the modification, which substituted PBXN-5 for composition A5.

Stresau Laboratory’s evaluation expertise has been used in these and many other products:

120 mm FMU143 MFF 20 mm FMU5001 MOFA 35 mm FMU5002 MPF 40 mm Gator MSF AAWSM GBU28 OCSW ACM GBU28 OICW ADAM GEMSS PACF ADS HE RAP PAM AIM9X HTSF Patriot AMRAAM Javelin PDM APREP JPF PGU9 AT4 JSOW Predator ATACMS LAW RAG BAT M1134 Rockeye BKEP M1134A SADARM BLU106B M230 Seagnat Brimstone M234 SFAFM Bushmaster M257 SFW CATFAE M423 SGT YORK CEM M427 SHUTTLE CMT M758 SLAM EFI M759 STAFF EPOP M762 Standard ERA M774 TDFD ESA M815 WASPM FLESCHETTE (2.75") MEHTF XM147 FMU139 MEMS XM234


Design Testing of M1134A3E1 LDC Fuze Customer: Naval Surface Warfare Center-Crane The Marine Corps funded efforts to improve reliability and increase user confidence by modifying the design of the M1134A3E1 LDC fuze. The proposed fuze modifications are intended to correct the tendency for premature initiations.

Primary Explosive Study Customer: Government & Prime Contractor Stresau is assisting particular customers, and the energetics community as a whole, with test, characterization and analysis of several new primary explosives. These materials are intended to meet specific criteria, such as environmentally acceptable, sensitivity, output, availability of constituents and stability as replacements for existing materials in new or legacy systems.

Hard Target Smart Fuze (HTSF) Explosive Train Reliability Customer: Prime Contractor Stresau conducted a series of penalty tests to determine explosive train reliability in the Hard Target Smart Fuze (HTSF) system. Varicomp penalty tests were performed at interfaces in the system to validate the customer’s design options.

Explosive Train Investigation for Objective Crew Served Weapon (OCSW) Customer: Prime Contractor The sophisticated OCSW air-burst munition requires several explosive interface points to achieve its complex mission. Stresau’s ongoing assessments of interfaces inform the customer of the safety and reliability of various design configurations.

Where in the world? Stresau Laboratory, Inc. is situated on a 130-acre tract ten miles northwest of Spooner, Wisconsin. Spooner is approximately 120 miles northeast of metropolitan area of Minneapolis & St. Paul, Minnesota (MSP airport). Stresau has operated continuously since 1961 on this site adjacent to Dunn Lake. Administration, research, test and evaluation, production and inventory are all at this site. Additional acreage is owned by the company inside a county forest preserve, which is used for testing charges that exceed the capacity of the Dunn Lake bunkers. Coming to visit? Let us know and we’ll send you the map along with some links to local attractions. Spooner is a popular vacation destination the year around.

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Lead Azide, RD-1333 certified to MIL-L-46225C Stresau has exclusive distribution in the US Defense market of Lead Azide manufactured by DynITEC of Troisdorf, Germany. This includes Lead Azide, RD-1333 certified to MIL-L-46225C. The Explosives Material Qualification Board (EMQB) approved in March 2010 Stresau’s test plan for qualifying this material for use in US Government contracts. The test plan included a long-term aging study the data from which was collected and reported to the EMQB in April 2011. EMQB approval followed and Stresau took delivery of production quantities September 2011 and the material is now available to the energetics community. The EMQB approval is a qualification over and above the MIL-L-46225C requirement which the material has met. A characteristic of particular importance to its use is the bulk density of 1.47 g/ccm; comfortably passing the 1.1 requirement which translates to better performance. DynITEC’s material is certified to MIL-L-46225C. The single exception taken is to the packaging which is an improved configuration: .8 kg (NEW) of RD-1333, wetted in an alcohol and water mix, is placed in a conductive bag, which is placed in a screw-lid conductive container (~8 cm diameter). Up to three of these

inner containers are placed in the outer conductive plastic drum (~30 cm diameter drum, ~20cm mouth). The space in both inner and outer containers is, of course, filled with water-saturated material with anti-freeze solution. The packaging is a standard commonly used by DynITEC and has been approved by the competent authority of Germany.


Hazardous Materials Testing Is it hazardous? The question comes up – or should – in many circumstances:

• Product reformulation. • Change in packaging for

storage, transport or sale. • A waste of complex or

unknown origins. The question might be asked to satisfy internal health and safety concerns. Compliance with complex transportation, environmental, health and safety issues at the state, national or international level might be the driver. So could the need to reduce cost while maintaining safe storage, transportation and packaging. The risk to life and limb from even apparently benign or inert materials and articles is significant. Ignorance of the hazards or the regulations governing them is no defense against civil litigation or regulatory sanctions. Stresau Laboratory helps you manage these risks:

• Defining the specific situations in which your material may undergo a violent reaction. • Measuring the degree and extent of danger the reaction poses. • Providing regulatory compliant solutions for the threat.

Stresau Laboratory works with manufacturers, package designers and other testing laboratories to answer these questions with a responsible, cost-effective protocol. It starts with what the customer knows about the material, article or waste. That information is validated and, if need be, additional testing completes the picture of the hazard and the proper management of that hazard. This management includes proper packaging, labels, storage, transport and handling. Stresau Laboratory answers the questions on material hazard for explosives, flammables, oxidizers and corrosives. Stresau Laboratory often provides sub-contract support to packaging and materials testing organizations because, like our end-user customers, they need Stresau's expertise in the analysis of the particular hazards of explosive, reactive, pyrophoric or flammable materials. Hazardous waste clean-up contractors have used Stresau Laboratory HMT on-site to characterize the reactive hazards real-time as needed. Analytical laboratories call on Stresau to assess reactive hazards of samples before exposing laboratory personnel and delicate analytical equipment to reactive hazards. Stresau Laboratory does not perform testing for radioactive (Class 7) or Toxic and Infectious (Class 6) hazards but works with laboratories that do to provide a complete hazard characterization of a substance when needed. Is it hazardous? Yes! If you don’t know the answer.

Characteristics of similar materials

Characteristics of constituents

Test results by manufacturer

Initial hazard determination

Validation/revision of initial hazard determination

Stresau Experience & Capabilities

Regulatory Framework,Safety & Liability

Requirements

Class 1

Can Hazard Classification be

made?

Are there secondary hazards?

Have tests revealed unexpected hazard?

Hazard Classification

Appropriate tests and analysis

Class 2

Class 5

Class 6

Class 7

Class 8

Class 9

OtherRegs

HealthSafety

Class 3

Class 4

Yes

No No

Yes Yes

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Category Specification Test Name Sample Unit Explosives Explosives Explosives SS345314 (Sandia Lab Spec.) 5.9 Pressure Density Test 10 grams Explosives UN TDG (T&C), Sec 13 Test

Series 3 6 foot Propellent Drop

3 cubes Explosives TB 700-2 Chapter 5 (Mil Spec) Blasting Cap 5 cubes (2") Explosives UN TDG (T&C), Sec 15 Test

Series 5 Cap Sensitivity

3 liter Explosives TB 700-2 Chapter 5 (Mil Spec) Card Gap 4 kg Explosives UN TDG (T&C), Sec 15 Test

Series 5 DDT Test

3.5 liter Explosives MIL-STD 1751A (July 1995) Electrostatic Discharge (Method

1032) 10 grams Explosives UN TDG (T&C), Sec 16 Test

Series 6 External Fire Stack

varies packages Explosives UN TDG (T&C), Sec 15 Test

Series 5 External Fire Test

Explosives MIL-STD 1751A (July 1995) Friction (BAM, Method 1024) 5 grams Explosives UN TDG (T&C), Sec 13 Test

Series 3 Friction Sensitivity (BAM)

2 grams Explosives UN TDG (T&C), Sec 11 Test

Series 1 Gap Test (Liquid)

1 liter Explosives UN TDG (T&C), Sec 11 Test

Series 1 Gap Test (Solid)

1 liter Explosives TB 700-2 Chapter 5 (Mil Spec) IGN and Unconfined Burn 5 cubes (2") Explosives MIL-STD 1751A (July 1995) Impact (BOE, Method 1011) 5 grams Explosives TB 700-2 Chapter 5 (Mil Spec) Impact Sensitivity (BOE) 2 grams Explosives UN TDG (T&C), Sec 13 Test

Series 3 Impact Sensitivity (BOE)

1 grams Explosives MIL-STD-1751A (July 995) Ball Drop Impact Test (Method

1016) 2 grams Explosives UN TDG (T&C), Sec 11 Test

Series 1 Koenen Steel Shell Test

0.5 liters Explosives NOLTR74-40 (Nav Ord Lab) Large Scale Gap 10 lbs Explosives UN TDG (T&C), Sec 15 Test

Series 5 Princess Incendiary Spark

Explosives UN TDG (T&C), Sec 13 Test Series 3

Series 3, Liquid materials 1300 grams


Series 3, Solid materials 1000 grams


Single Package Test 3 packages

Explosives WS 5003;MIL-STD 1751A (July 1995)

Small Scale Gap Test (Method 1042) 30 grams


Small-Scale Burning Test 220 grams


Stack Test 18 packages


Thermal Stability, Part 1 50 grams


Thermal Stability, Part 2 150 grams

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Explosives TB 700-2 Chapter 5 (Mil Spec) Thermal Stability-Part 1 50 grams Explosives TB 700-2 Chapter 5 (Mil Spec) Thermal Stability-Part 2 50 grams Explosives UN TDG (T&C), Sec 11 Test

Series 1 Time/Pressure Test

25 grams Explosives MIL-STD 650A Vacuum Thermal Stability 25 grams Explosives MIL-STD-1751A Method 1061 Vacuum Thermal Stability 25 grams Explosives MIL-STD 650A Method 503.1.1 Vacuum Thermal Stability 25 grams Explosives NAVORD 0044811 Vacuum Thermal Stability 25 grams Explosives STANAG 4556 Procedure 1 Vacuum Thermal Stability 25 grams Explosives MIL-STD-650 Method 504.1.1 Reactivity/Compatibility using

VTS: 15 grams Explosives STANAG 4147 Test 1 Reactivity/Compatibility using

VTS: 15 grams Explosives TB 700-2 Chapter 5 (Mil Spec) Zero Gap 1 kg Explosives Additional

Explosives Additional

Fireworks BOE Chemical Analysis >8 Cylinder 3 units Fireworks BOE Chemical Analysis 1 Cylinder 3 units Fireworks BOE Chemical Analysis 2-4 Cylinder 3 units Fireworks BOE Chemical Analysis 5-8 Cylinder 3 units Bruceton Analysis All-fire Probability Modeling Additional Trials, per 10 5 grams Dynamite Tests Hercules Method Air Gap (Hercules Method) 1 case Fireworks APA Standard 87-1 APA Test Program Dynamite Tests 49 CFR 173 Appendix D Dynamite DOT Classifications Bruceton Analysis All-fire Probability Modeling Electrostatic Discharge Sensitivity 5 grams Bruceton Analysis All-fire Probability Modeling Friction (BOE) 5 grams Bruceton Analysis All-fire Probability Modeling Friction (BAM) 5 grams Bruceton Analysis All-fire Probability Modeling Impact (BOE) 5 grams Railroad Torpedo Spec

49 CFR Rifle Bullet Impact 5 cases

Railroad Torpedo Spec

49 CFR Thermal Stability 1 unit

Fusees 49 CFR 173.184 Thermal Stability 3 units Fireworks BOE Chemical Analysis Thermal Stability (DOT/AFSL) 1 units Dynamite Tests Velocity of Detonation 5 units Flammable Flammable Flammable Aerosols

Flammable Aerosols

49 CFR 173.115; UN TDG (T&C), Sec. 31

Aerosol foam flammability test 4 dispensers

Flammable Aerosols

49 CFR 173.115; UN TDG (T&C), Sec. 31

Enclosed space ignition test 3 dispensers

Flammable Aerosols

49 CFR 173.115; UN TDG (T&C), Sec. 31

Ignition distance test for spray aerosol 6 dispensers

Flammable Liquid Flammable Liquid ASTM D 92 Flash and Fire Point, Cleveland

Open Cup 250 ml Flammable Liquid 49 CFR 173.120; UN TDG (T&C),

Sec. 32 Flash Point (Setaflash)

50 ml Flammable Liquid ASTM D 93, ASTM E 134 Pensky-Martens Closed Cup

Flashpoint 1 litre Flammable Liquid 49 CFR 173 Appendix H;UN TDG

(T&C), Sec. 32 Sustained Combustibility (Open Cup Combustibility) 50 ml

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Flammable Solid Flammable Solid UN TDG (T&C), Sec. 33 Class 4.1 Burn Rate (Readily

Combustible) 0.25 litre Flammable Solid UN TDG (T&C), Sec. 33 Class 4.1 Preliminary Screen

(Readily Combustible) 0.1 litre Flammable Solid EC# A-10 (Euro Community) Flammability 3000 ml Flammable Solid OSHA Standard OSHA Burn Rate 1500 ml Flammable Solid EC# A-16 (Euro Community) Self Ignition 125 cubic mm Flammable Solid ASTM D4359-8-2000 Solid/Liquid Test 1 quart Combustible Combustible Spontaneously Combustible

UN TDG (T&C), Sec. 33 Class 4.2 Liquid Pyrophoric 100 ml

Spontaneously Combustible

UN TDG (T&C), Sec. 33 Class 4.2 Self Heating 2500 cc

Spontaneously Combustible

UN TDG (T&C), Sec. 33 Class 4.2 Solid Pyrophoric 10 grams

Dangerous When Wet

UN TDG (T&C), Sec. 33 Class 4.3 Water Reactivity 80 grams

Metals, Metal Powder & Metal Dust

NFPA 484 Standard for Combustible Metals/Preliminary Screen

Oxidizer Oxidizer Oxidizer 49 CFR 173.127;UN TDG (T&C),

Sec. 34 5.1 Oxidizer Test (Liquid)

15 grams Oxidizer 49 CFR 173.127;UN TDG (T&C),

Sec. 34 5.1 Oxidizer Test (Solid)

200 grams Organic Peroxide OPPSD Tests Flash Point (Setaflash closed cup) 20 ml Organic Peroxide OPPSD Tests Large Scale Confined Burn 1 unit Organic Peroxide OPPSD Tests Rapid Heat 20 ml Organic Peroxide OPPSD Tests Small Scale Confined Burn 1 quart Organic Peroxide OPPSD Tests Unconfined Burn 400 ml Organic Peroxide/Self-Reactive

Organic Peroxide/Self-Reactive

Organic Peroxide/Self-Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 21

Cavitated Gap (Liquids Only)

1.5 liters Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 23

Deflagration Test


49 CFR 173.128; UN TDG (T&C), Sec. 24

Deflagration Test in package

3 packages Organic Peroxide/Self-Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 22

Detonation Test in Package

3 packages Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 25

Dutch Pressure Vessel

200 grams Organic Peroxide/Self-Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 21

Gap Test (Solid)

1.5 liters

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 28

Heat Accumulation Storage Test

1 liters Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 25

Koenen Steel Shell Test


49 CFR 173.128; UN TDG (T&C), Sec. 28

SADT Pressure/Temperature

1 packages Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 28

SADT Temperature only

1 packages Organic Peroxide/Self-Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 23

Time/Pressure Test


49 CFR 173.128; UN TDG (T&C), Sec. 26

Trauzl Block (modified)

20 grams Organic Peroxide/Self Reactive

49 CFR 173.128; UN TDG (T&C), Sec. 25

USA Pressure Vessel

50 grams Toxicity Toxicity Toxicity 49 CFR 173.134 Dermal Toxicity 30 grams Toxicity 49 CFR 173.134 Oral Toxicity 30 grams Corrosivity Corrosivity Corrosivity 49 CFR 173.136; UN TDG (T&C),

Sec. 37 Aluminum

9 liters Corrosivity 49 CFR 173.136 Corrositex Skin Test 5 ml Corrosivity 49 CFR 173.136 Rabbit Skin Test (live test) 50 ml Corrosivity 49 CFR 173.136; UN TDG (T&C),

Sec. 37 Steel

9 liters Miscellaneous Miscellaneous Fertilizer Tests UN TDG (T&C), Sec. 38 Fertilizer Trough Test

12 quarts, dry

Fertilizer Tests Old CFR Ammonium Nitrate Oil Absorption 20 grams Fertilizer Tests Old CFR Burn Tower Test 160 lbs Compressed Gas Cylinders

Compressed Gas Assn. Chimney Fire Test 3 cylinders

Fertilizer Tests Old CFR Fertilizer Detonation & Burn Tower 175 lbs Fertilizer Tests Old CFR Fertilizer Detonation Resistance 15 lbs Tear Gas Leakage 49 CFR Tear Gas Leakage 3 units Additional Tests Additional Tests Bomb Calorimetry (Heat of Combustion)

ASTM D 240-02 (2007) Bomb Calorimetry (Heat of Combustion)

5 grams Charcoal (Proximity Test)

Charcoal (Proximity Test) 1250 grams

Differential Scannning Calorimetry (DSC) (Method 1072)

MIL-STD 1751A (July 1995);ASTM E 537-02

Differential Scannning Calorimetry (DSC) (Method 1072)

5 grams

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Freezing Point Freezing Point 50 grams Friction Sensitivity (BOE)

Friction Sensitivity (BOE) 5 grams

Moisture Content (Uniform weight)

Moisture Content (Uniform weight) 50 grams

pH Measurement of sample

pH Measurement of sample as received

Prima Cord Velocity

Prima Cord Velocity 10 feet

Burn Test IATA Dangerous Goods Regulations Special Provision A75

Burn Test TBD

Additional Services & Charges

Additional Services & Charges

Melting Point 1 grams Boiling Point 1 ounce Accelerated Shelf Life

TBD


Quality: ISO 9001:2008 Stresau’s ISO 9001:2008 certification is from BSI an ANAB accredited registrar of quality standards. ISO 9001 is by far the world’s most established quality framework, currently being used by over three-quarter million organizations in 161 countries, and sets the standard not only for quality management systems, but management systems in general. Stresau obtained certification from BSI, founders of the management system standard BS 5750, the forerunner to the ISO 9000 series. It remains a key member of the ISO 9000 technical committees.

Environmental Standard: Wisconsin Green Tier Green Tier is based on a collaborative system of contracts and charters crafted jointly by participating businesses and the Wisconsin Department of Natural Resources (WDNR). These contracts and charters streamline environmental requirements in many cases and encourage new environmental technologies. Major elements of the program were developed in advisory committee meetings between 2000 and 2003, culminating with the signing into law on April 17, 2004 by Governor Doyle. Green Tier is designed to help environmentally responsible companies achieve environmental and economic gains. As of September 2009, the DNR has entered into 5 charters, 2 Tier 2 contracts, and 23 Tier 1 (with a total of 33 facilities) agreements. Stresau submitted an application to be considered as a program participant in January 2007, and became a Tier 1 designated participant in April 2009. On April 30, 2009, Matt Frank, WDNR Secretary, presented

Wayne Hanson, Stresau President, with the Green Tier charter and letter of acceptance at an on-site presentation ceremony.


Management and Personnel As profiles below demonstrate, top management is technically experienced and close to the operations.

WAYNE HANSON: President Education: EE, 1986 Experience: Mr. Hanson is the owner and President of Stresau Laboratory. Mr. Hanson has been with Stresau since 1985, first as a Program Manager and then the Development Manager. In 1996, Mr. Hanson purchased Stresau from his father, Ralph Hanson.

He has developed several electrically initiated cable cutters and continues his technical involvement. Additionally his experience and training in Computer Aided Design (CAD) and computer programming (PASCAL) is called on in the design and execution of tests for other programs and areas of the organization. His knowledge of electronics is used for designing and building both analog and digital test data in-put fixtures and connections.

MICHAEL J. PESKO: Chief Operating Officer Education: B.A. Chemistry in 1973 Experience: Mr. Pesko’s responsibility for general management of Stresau follows a long career of both broad technical and management experience with the company, as Manager of the Development Department. Annual and extensive management training in strategic planning and operational management enhance his considerable experience in this area. Current responsibilities are for the day-to-day operation of Stresau and implementation of its strategic direction. He executes and monitors Stresau’s commitment to low cost, on time and high quality products for customers, stimulating work environment for employees and a good corporate member of the community.

WANE OLSON: Program Management Supervisor, Manufacturing Manager Education: B.S. in Mechanical Engineering in 1983 Experience: Mr. Olson joined Stresau Laboratory, Inc. in 1989 with 5 years experience as Project Engineer in the ordnance industry after completing his BSME at the University of Minnesota. As Program Manager, he has responsibility for managing development contracts involving manufacturing usually involving prototype equipment as well as build-to-print contract assignments.

BECKI AMENDT: Development Manager Experience: Ms. Amendt is Manager of the Development Department for Stresau Laboratory. Her current responsibilities include the planning, direction, coordination, and control of the activities involved in providing development, testing and evaluation services for ordnance, hazardous materials, and commercial products. These development activities are for Stresau’s own initiatives and those of its customers. As a Program Manager, Ms. Amendt conducted safety and reliability tests of various programs including SLAM, AMRAAM, Javelin, OICW, OCSW, Brimstone and many more. She is currently working on the MEMS, TOW and the Counter Mines System, as well as, a commercial fire safety device.

MYLES DONEGAN: Explosive Preparation Manager Education: B.S. in Chemistry from East Tennessee State University Pursuing M.S. in Chemistry from Lehigh University Experience: Mr. Donegan spent several years as both a process and analytical chemist with a major US prime contractor with a focus on energetic materials. Starting with


Stresau in 2011 he has applied both academic and practical experience to existing back-line operations and the introduction of new materials synthesis and processing.

JOEL D. BLAZER: Quality Manager Education: B.S. Industrial Technology, Mfg., Engineering, in 1991 from UW-Stout; Certified Manufacturing Technologist certification current; A.A. Electromechanical Technology, in 1988 from Chippewa Valley Technical College. Experience: Mr. Blazer joined Stresau Laboratory, Inc., in 1992 as a Quality Engineer and assumed department manager duties in 1994. Prior to that he completed his education in related technical disciplines and worked in manufacturing organizations in a variety of positions. He has developed a quality audit system at Stresau which has itself passed several customer quality audits with commendation. He is active in the local ASQC chapter and SME.

JAY HANSON: Development Technician Education: B.S. Geophysics, University of Minnesota, 1983 Experience: Originally spent his career working in the mineral exploration end of the mining industry, both in government research and private enterprise capacities. He has worked in many parts of North America on a variety of projects in the search for base and precious metals using modern geophysical detection methods. He has also worked as an independent geophysical consultant in special applications for the mining and geotechnical engineering industries in the mapping of subsurface features such as caves, fault structures, water table, utility lines, and abandoned mine shafts. The sophisticated electronics of this field, in part, prepared him for the career move to Development Technician in charge of automated bridgewire welding and laser welding of energetic devices in small and medium-sized quantities.

STUART V. OLSON: Senior Scientist Education: B.S. in Zoology in 1976 Experience: After more than two decades as Manager of Stresau’s Explosive Preparation Mr. Olson has stepped out of its management to focus on the science. Mr. Olson came to Stresau after a number of years as Research Coordinator in the UW Medical School laboratories. Recent accomplishments include development of a high temperature resistant stab sensitive primer mixture and development of processes to granulate pyrotechnic delays for precise uniformity.

RONALD L. CARLSON: Chemist Education: A.A. in Chemistry 1977, additional chemistry studies at University of Minnesota, Duluth Experience: Mr. Carlson came to Stresau in 1986 already experienced with production of pyrotechnic, primary and secondary explosives. He was chemist in charge of previous Lead Azide production at Stresau and has managed numerous commercial contracts for delivery of energetic materials. This is in addition to the day-to-day demands of supplying Stresau’s own internal demand for manufacture and processing of energetics. These include primaries, secondaries, flash powders, spot charges and delays. He has performed analysis of Lead Azide and other energetics and headed up facility and process improvement programs for manual, remote and robotic mix/blend units.

KASEY KRONLUND: Development Program Manager Education: B.S. in Business Administration, UW-Stout Experience: Mr. Kronlund joined Stresau as a Development Technician in 2004 advancing to Development Program Manager where responsibilities have focused on


small and intermediate quantity production and manufacture of prototype components. He is pioneering energetic applications with 3-D printing in both Stresau and customer defined components.

JASON DANIELSEN: Manufacturing Program Manager Education: B.S. in Business Administration with a Technical Component in Service Management from UW-Stout; Experience: Mr. Danielsen joined Stresau in 2005 and held positions in Manufacturing Assembly and Quality Inspector prior to advancing to Program Manager. As a Program Manager his assignments have included the Patriot ETA and multi-bridge detonators for commercial applications. He has managed production of several electric detonators for both US and foreign defense customers.

AARON DAVISON: Manufacturing Program Manager Education: Associate Degree from CVTC in Nano Science; Experience: Mr. Davison has had several manufacturing positions that included MEMS scale assembly, precision welding and material processing technologies. These have assisted in his successful assumption of PM duties for some of the largest volume production contracts at Stresau. These include prime contracts for Blasting Caps and associated Squibs.

RICHARD HOFF: Compliance Specialist Experience: Mr. Hoff joined Stresau in November of 2001 in the new position of Compliance Specialist, assuming the responsibilities for the Environmental, Safety and Human Resources areas. Mr. Hoff brings over 25 years of environmental, safety, health, quality assurance and senior management experience to Stresau. Most recently, Mr. Hoff was in the position of Corporate Technical Services Director for a major mid-west window manufacturer, responsible for the environmental, safety, health and quality assurance program for four manufacturing facilities. Past training and experiences include certification as a Professional Environmental Auditor, target training in safety management and ergonomics, and past instructor for the Supervisor’s Safety Management program at Wisconsin Indianhead Technical Institute (WITC), Rice Lake, WI campus.

LAURIE K. KOENIG: Manager of Accounting & Administration Education: B.A. Business/Accounting in 1981; MBA Finance in 2001 Experience: Ms. Koenig joined Stresau in 1990 with 9 years of experience in accounting and finance for Unisys Defense Systems. Ms. Koenig is responsible for all accounting and treasury functions at Stresau as well as document control and general administration.

WILLIAM W. STEWART: Marketing Manager Education: B.S. in Journalism in 1976; MBA in Management in 1987 Experience: Mr. Stewart is a primary communication link between Stresau and its customers. He is responsible for initiating and coordinating the activities, which result in timely responsive proposals to meet customers’ needs. This presentation of proposals and continuing customer contact links Stresau’s customers and the technical services Stresau has to offer. His newspaper experience and business education serve Stresau and its customers’ needs to communicate quickly and accurately among many disciplines.


Capability and Facility at Stresau Laboratory Stresau Laboratory’s facility optimizes the conflicting demands of flexibility for small programs and fixed tooling for extended production. In each case one factor is maximized: safety. Quantity and distance requirements for building placement and use are strictly observed, as are environmental operating standards and conditions. Stresau understands that safety is an important

end unto itself but also that it is impossible to meet delivery, quality and price requirements over the long-term in a facility that is not built and operated safely.

Test and Evaluation The Test and Evaluation building is designed to facilitate the T&E functions of the Laboratory. As such, it is equipped with numerous explosive test chambers to accomplish Lot Acceptance Testing of explosive devices; Bruceton, Langlie, Proportional Gap, and other safety and reliability testing; and other T&E needs that require initiations of the device under test. Located here is the electronic equipment necessary to obtain testing data, such as detonation velocities, and equipment that condition, initiate, and otherwise affect the devices being tested. The equipment includes oscilloscopes, power supplies, constant current sources, and temperature and humidity chambers. Also located are equipment peculiar to the needs of the Laboratory, such as firing circuits, and test equipment with which such things as voltage, capacitance, or current can be varied to satisfy differing requirements.

Production The primary consideration in the design of the Production buildings (as well as all other explosive-containing structures) is the duty to satisfy safety requirements. Some of the facets considered in building design are quantity and type of explosives used in the buildings, wall thickness and construction, static electricity dissipation, barrier placement and design, quantity/distance relationships, humidity control, and personnel limits. The objective of building design at the Laboratory emphasizes the safe storage, flow, handling, and use of explosives and explosive containing devices. The humidification system, for example, is pneumatically, and not electrically, operated.

Explosive Preparation & Chemical Research The Explosive Preparation building is where the preparation of explosives used by the operations of the Laboratory occurs. In addition, the production of energetic materials occurs in this building. Located within the building is the equipment needed to handle the special requirements of explosive preparation and/or production, such as remote milling, blending, drying, weighing and dispensing operations. From the Explosive Preparation building, energetic material is transported to the point of use, or to long-term storage.

Stresau Laboratory, Inc. of 20Profile of Experience & Capability The Chemical Research building houses the Laboratory’s Hazardous Material Testing and Classification resources. Equipment assets acquired from the Bureau of Explosives are located here. The building has the layout and equipment that enable test stations for such tests as Scanning Differential Calorimetry to be performed in it. Friction, impact and electrostatic sensitivity tests for explosive formulations are conducted here.

State of the Art Manufacturing Laser welding provides for hermetic seals and smooth joining of steel or stainless steel components. Stresau’s laser welding is particularly suited to the typical cylindrical assemblies found in energetics and fuzes but is just as well suited to medical devices, tools or high-end bicycle components. The StarWeld tool is an Nd:YAG, with 100 watts of power and a maximum pulse energy of 80 Joules. Its precisely controlled bed adapts to millimeter-sized components while its open architecture can accommodate units of much larger dimensions. Automatic bridgewire welding of glass-to-metal seal components increases throughput while insuring repeatable quality at a production pace. On-board post-weld resistance testing ensures uniform high quality. While specifically designed to produce headers for M100 sized detonators in high volume, its flexibility supports Stresau’s ability to meet its customers’ requirements for customized variants of such standard components. The ABW is typically employed in volumes above ten thousand units. Stresau is frequently called on for smaller quantities and skilled welders meet these demands. Stresau’s adaptable approach to loading tools permits economic production for everything from prototypes to full production.

Stresau Laboratory, Inc. of 20Profile of Experience & Capability Summary Profile Stresau Laboratory, Inc. was established in Northwest Wisconsin by Richard Stresau in 1961. It continues to set the standard for manufacturing and testing energetic components and materials.

Manufacturing: Stresau Laboratory manufactures primers, blasting caps, detonators, leads, gas generators and actuators by the dozens and by the millions. Components for defense customers are found in large and medium caliber; missile and undersea systems. Commercial applications are in life-saving devices and high voltage transmission lines.

Development: Stresau Laboratory is the premier authority on fuze train development and analysis, the study of initiation phenomenon and test design for energetic systems. Systems include Patriot, CEM and OICW and OCSW.

Hazardous Materials Testing: by Stresau Laboratory satisfies specific DOT Hazard Classification, UN Dangerous Goods Transport regulations as well as analysis of wastes, new products and for post-incident evaluations. Customers include manufacturers, shippers and analytical laboratories.

R. Stresau Laboratory, Inc., dba: Stresau Laboratory, Inc Certifications & Standards

ISO 9001:2008 Certificate No.: FM 546885, Registered by BSI Calibration to ANSI Z540, ISO 10012-1

Certified to Wisconsin Green Tier Environmental Management System Codes

Manufacturing SIC: 3483; NAIC: 332993 Ammuntion (not small)

Development and Hazardous Material Testing

SIC: 8734; NAIC: 541380 Testing Laboratory

Facility & Cage 62387 Communication

Telephone 715-635-2777 (see extensions below) Facsimile 715-635-7979

Mail, Ship & BillAddress

Stresau Laboratory N8265 Medley Road Spooner, WI 54801-7819

Web site http://www.stresau.com e-mail [email protected]

Personnel Telephone ExtensionPresident Wayne Hanson 131

Chief Operating Officer Mike Pesko 143 Development Manager Becki Amendt 129

Manufacturing Manager Wane Olson 153 Explosive Preparation Manager Myles Donegan 171

Haz Mat Testing Manager Tom Basham 166 Quality Manager Joel Blazer 136

Marketing Manager Bill Stewart 137 Accounting Manager Laurie Koenig 144

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