Currently, the processing fluids used for non-aqueous slurry coating processes of explosives contain chemicals of concern. The use of non-aqueous fluids as mixing media for the development and processing of explosive formulations is needed for all formulations containing aluminum and/or water-soluble ingredients. The objective of this effort will be to identify a replacement energetics processing fluid that does not contain chemicals of concern and demonstrate this fluid’s ability to successfully produce and manufacture key energetic formulations that require a non-aqueous inert mixing medium.

DEVCOM Armaments Center and Naval Surface Warfare Center, Indian Head (NSWC IHD) will approach this issue in a direct manner. Two energetic formulations that require a non-aqueous method of slurry coating for production have been chosen as the main focuses of this study: PAX-64 and PBXN-13. Compatibility testing has previously been completed on these formulations’ constituents and ethylene glycol. The analytical, safety, and characterization test results of each formulation trial’s product will be compared to results of legacy values for PAX-64 and PBXN-13. Upon achievement of satisfactory results, processes will be scaled up from lab scale batches to medium scale and ultimately manufacturing equivalent scale batches at NSWC IHD.

The successful completion of this study will result in a slurry coating process for two high explosive energetic formulations. Eliminating the current fluid will remove emerging chemicals of environmental concern and assure the continued production of key weapons systems that utilize these formulations. (Anticipated Project Completion - 2026)