hazard assesment testing for sm3 blockia missile

Hazard Assessment Testingof the SM-3 Block IA Missile

Presentation for theNDIA Gun and Missile Systems Conference

25 April 2007

Dave HouchinsDahlgren Division, Naval Surface Warfare CenterTest & Evaluation Division (Code G60)

Hazard Assessment Testing of the SM-3 Block IA Missile

Outline• Description of SM-3 Block IA missile• Hazard Assessment Test Program• Test methodologies• Summary of results• Lessons-learned


MK 72 Booster

MK 104 Dual ThrustRocket Motor

Third StageRocket Motor

GuidanceSection

Kinetic Warhead(inside Nosecone)

Nosecone

StagingAssembly

Steering Control Section

SM-3 Block IA Missile• Sea-based component of the Ballistic Missile Defense system• Launched from Vertical Launching System of DDG-class ships

– Approximately 22 ft length x 13.5 in diameter• MK 72 booster ~21 in diameter

– Contains ~2065 lbm propellant– Designed for MK 21 MOD 2 VLS canister

• Total mass of all-up round ~6300 lbm (i.e., missile and canister)• Exo-atmospheric intercept using Kinetic Warhead


Hazard Assessment Test Program for SM-3

Functional Testsof Components

Near Miss Shock

2005/2006SM-3 Block IA

Transportation VibrationShipboard Vibration

28-Day Temperature & Humidity


1999SM-3 Block 0

40-ft DropAft-end down

28 Day T&H

Fast Cook-offThird Stage Rocket Motor

Kinetic Warhead



Launch Shock


SM-3 Block I2004

Slow Cook-offThird Stage Rocket Motor

Kinetic Warhead

40-ft DropHorizontal




Fast Cook-offThird Stage Rocket Motor

Bullet ImpactThird Stage Rocket Motor

Kinetic Warhead

Fragment ImpactThird Stage Rocket Motor

Kinetic Warhead

Insensitive Munitions Tests(individual sections)

Environmental Tests(encanistered missile)


28-Day / 4-Day Temperature and Humidity (T&H) Test Method• Encanistered missile cycled between hot/humid and cold environments

– Conditions based on environmental profile for logistics life-cycle• +130F with 95% RH for hot/humid environment• -20F for cold environment

– 1 cycle includes 24-hr (min) exposure to each environment • Tests conducted using programmable environmental chamber• Test methods identical except for duration

– 14 cycles for 28-day T&H; 2 cycles for 4-day T&H

Time (hr)

Nominal RH(uncontrolled)

0

-20

60

-40

0

20

40

80

100

120

140

160

Tem

pera

ture

(°F)

010

20

30

40

50

60

70

80

90

100

5 10 15 20 25 30 35 40 45 50 55 60

Temperature

Relative Humidity

Rel

ativ

e H

umid

ity (%

)

Beginning ofNext Cycle


• Encanistered missile subjected to random vibration IAW MIL-STD-810– Simulate transportation by truck over improved roads– Input applied through 3 orthogonal axes; 1 axis at a time– 3 hr/axis duration to simulate 3000 miles over-the-road transport

• 2 hydraulic actuators used to provide input at each PHS&T skid

Transportation Vibration Test Method

Vertical Axis

Longitudinal Axis

Transverse Axis


Transportation Vibration Input Profile

5 10 20 50 100 200 500.00001

.00002

.00005

.00010

.00020

.00050

.00100

.00200

.00500

.01000

Frequency (Hz)

Pow

er S

pect

ral D

ensi

ty g

^2/H

z.0200

.0500

.1000

Vertical AxisTransverse AxisLongitudinal Axis


Shipboard Vibration Test Method• Encanistered missile subjected to random vibration to simulate shipboard

environment– Input profile and duration based on shipboard measurements in VLS cells

• 4 – 200 Hz frequency range• Input spectrum encompasses full range of ship speeds and sea states• 39-hr/axis to simulate anticipated deployment durations

– Input applied through 3 orthogonal axes; 1 axis at a time• System-specific tailored test requiring approval from NAVSEA 05T

– Most systems tested IAW MIL-STD-167• Sinusoidal vibration across 5 – 50 Hz frequency range

• Accomplished using UD-4000 electrodynamic shaker– Special fixtures used to provide input at correct interfaces with canister


Shipboard Vibration Input Spectrum


Transverse ShipboardVibration Fixture

UD 4000Shaker

VLS Dog-Down

Fixture

All-Up Missile inMK-21 Canister

DeckInterfac

eFixture

HydraulicBearings

Shipboard Vibration Test Setup (Transverse Axis)


Lateral SupportStructure

UD 4000Shaker

VLS Dog-down

Fixture

All-Up Missile inMK-21 Canister

Deck InterfaceFixture

Shipboard Vibration Test Setup (Longitudinal Axis)


Near Miss Shock Test Method• Accomplished using DS-3 Shock Machine

– Large-displacement, pendulum-type impact shock machine– Highly-tunable design

• Continuously adjustable pendulum impact velocity• Unique adjustable fixture permits input through 3 principal axes of item

• System-specific tailored test requiring approval from NAVSEA 05P3– Alternative to Heavyweight Test (i.e., “Barge Test”) of MIL-S-901– Input levels tuned to actual field measurements


Near Miss Shock Test Setup

Pendulum

Transfer Beam Assembly

Carriage

Encanistered Missile

VLS Dog-Down Fixture

SpringsBrakes

Cradle

Deck Interface Simulator Fixture


Tuning of Input for Near Miss Shock Test

Input

LongitudinalComponent

TransverseComponent X - Component

Y - Component

TransverseComponent

Clocking Angle

Obliquity Angle

Pendulum drop height – peak velocityProgrammer pad thickness – initial accelerationBrakes & Springs – initial pulse duration; magnitude of neg. velocityObliquity/clocking – Longitudinal and Transverse components


Representative Response Data

RequirementAccelerometer 1Accelerometer 2Accelerometer 3Accelerometer 4Accelerometer 5


Configuration of Kinetic Warhead

• 3 propellant grains in Solid Divert and Attitude Control System (SDACS)– Pulse I grain is TP-H-3510 propellant– Pulse 2 grain is TP-H-3511 propellant– Sustain grain is TP-H-3512 propellant

• SDACS case is graphite-epoxy composite

MTA ThrustersSustain Grain

Pulse 1 Grain

Pulse 2 Grain

Guidance Unit

Ejector Assembly

Cryogenic Gas Bottle(Nitrogen @ 6000 psi)


Configuration of Kinetic Warhead for Insensitive Munitions Tests

• Kinetic Warhead assembled to simulated Guidance Section shroud– 13.625-in OD annular aluminum cylinder with ½-in thick aluminum closure

plate– Guidance Unit simulated using high-fidelity mass model– Cryogenic gas bottle present and fully-charged

• Block IA Nosecone installed over Kinetic Warhead– Secured to simulated Guidance Section shroud in same manner as

tactical missile– All Nosecone explosive components present

Nosecone

SDACS

Nosecone

End Cap(simulated Guidance Section)

X-SMDC

Cryogenic Gas Bottle

Guidance UnitEjector

Nosecone

SDACS

Nosecone

End Cap(simulated Guidance Section)

X-SMDC

Cryogenic Gas Bottle

Guidance UnitEjector


General Configuration of Third Stage Rocket Motor

• 2 propellant grains– Pulse I grain is TP-H-3518A propellant– Pulse 2 grain is TP-H-3518B propellant

• Case sidewall is filament-wound graphite-epoxy composite• Toroidal cold gas bottle contains pressurized nitrogen

Composite Case

Toroidal ColdGas Bottle

Pulse 1 Grain

Pulse 2 GrainIgnition Tube


Configuration of Third Stage Rocket Motor for Insensitive Munitions Tests

• TSRM assembled with end caps to simulate adjoining missile sections– Each end cap is 13.72-in OD annular aluminum cylinder with ½-in thick

closure plate– Aft end cap secured using 4 explosive bolts

• Replicate configuration of tactical missile


Bullet Impact Test Method• Item impacted by three (max) 0.50-cal AP projectiles

– Velocity of 2800 ± 200 ft/s– Bullets fired at 50 ms intervals using three 50-cal Mann barrels

• Trajectory of bullets perpendicular to longitudinal axis of test item– Bullets aimed to pass through center of SDACS propellant in KW– Bullets aimed to pass through Pulse II grain and ignition tube in TSRM

• Instrumentation and data collection IAW MIL-STD-2105B– Gun firing times– Bullet velocities– Air shock– High-speed video record of events– Post-test recovery and characterization of remains


Bullet Impact Test Setup


Fragment Impact Test Method• Item impacted by three ½-in mild-steel cubes

– Velocity of 6000 ± 200 ft/s– Cubes launched using 60mm smoothbore gun and unique FRP sabot

• Trajectory of cubes perpendicular to longitudinal axis of test item– Aimed to pass through center of SDACS propellant in KW– Aimed to pass through Pulse II grain and ignition tube in TSRM

• Instrumentation and data collection IAW MIL-STD-2105B– Cube velocities– Air shock– High-speed video record of events– Post-test recovery and characterization of remains


Fragment Impact Test Setup

PressureGauge 1

PressureGauge 2

PressureGauge 3

PressureGauge 4

15' R

90°

PressureGauge 5

PressureGauge 6

34' R

Plan View

Velocity Screens (3)

Test Item(assembled in test fixture)

FragmentShield60mm Gun

~7'

~25'~4.5' ~4.5'

Forward End

22' R


Fast Cook-Off Test Method• Item suspended above pool of burning JP-5 aviation fuel

– Average flame temperature >1600F– 30-ft x 30-ft fuel basin used to ensure complete immersion within flame

• Instrumentation and data collection IAW MIL-STD-2105B– Flame temperature– Air shock– Video record of events– Post-test recovery and characterization of remains

• Pretest modeling to predict time to reaction– 1-D model to examine radial heat transfer through case sidewall– Examined two bounding flame temperature conditions

• 1600°F average flame temperature• 2000°F average flame temperature


Fast Cook-Off Test Setup


ReactionsObserved

Predicted Temperature at Liner/Propellant Interface During TSRM Fast Cook-Off

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

0 1 2 3 4 5 6 7 8 9 10 11 12

Time (minutes)

Tem

pera

ture

(deg

F)

1600°F Avg Flame Temp2000°F Avg Flame Temp

FireBuild-Up

AblativeBurn-Off

Predicted Time of Propellant Ignition


Summary of Test Results

Third Stage Rocket Motor: Type IV reaction (deflagration)Fast Cook-Off

Kinetic Warhead: Type IV reaction (deflagration)Third Stage Rocket Motor: Type III reaction (explosion)

Fragment Impact

Kinetic Warhead: Type IV reaction (deflagration)Third Stage Rocket Motor: Type III reaction (explosion)

Bullet Impact

No safety-related anomaliesNear Miss Shock

No safety-related anomalies4-Day Temperature & Humidity

No safety-related anomaliesShipboard Vibration

No safety-related anomaliesTransportation Vibration

No safety-related anomalies28-Day Temperature & Humidity

ResultTest


Lessons Learned• Multi-shaker setup used for Transportation Vibration test introduces additional

issues related to phase control– Currently not explicitly addressed in MIL-STD-810– Accepted / best practices still evolving

• Not possible to achieve same input levels at both ends of canister in Shipboard Vibration test due to fixture dynamics– Fact-of-life constraint for single-shaker setup using large, complex fixture– Problem most pronounced at higher frequencies– New state-of-the-art facility at NSWC/Dahlgren will enable multi-shaker

testing in vertical orientation• Near Miss Shock test demonstrated capability to replicate real-world triaxial

shock input to large encanistered missile using pendulum-type shock machine– Potential alternative to “Barge Test” for some systems

• Subject to approval by NAVSEA 05P5 on case-by-case basis• May reduce system design risks


More Info• Test program documented in two NSWCDD technical reports

– NSWCDD/TR-06/47, Standard Missile - 3 Block IA Hazard Assessment Test Results

• Draft currently in final review– NSWCDD/TR-06/48, Standard Missile-3 Block IA Near Miss Shock

Qualification Test Report

hazard assesment testing for sm3 blockia missile

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