Contribution: Munitions and Safety

The substances used, sometimes in combination, determine not only the performance but also the safety of a weapon or munitions. While safety has improved over the years, continued surveillance is required throughout the life cycle of munitions. From their production, storage and transport to their use and disarmament.

New weapons and corresponding countermeasures are an ever-present feature of warfare. As the arenas of warfare change, and with terrorism on the rise, new demands are being imposed on munitions and weapon platforms. Precision and non-lethal weapons are being developed, with the need to reduce collateral damage in clear evidence. The knowledge, expertise and facilities required to stay ahead in a highly technological field are now invaluable.

The TNO Prins Maurits Laboratory (TNO-PML) is equipped with experimental facilities and is run by trained and experienced staff who support and advise customers on questions such as those related to the safety, performance and lifetime prediction of munitions and explosives.

Munitions and Safety: Insensitive Munitions (IM)

Accidents still occur during the military use of explosive substances. While the risk has been minimised, thanks to good safety measures and training, it persists. Recent examples confirm that numerous casualties and extensive damage are often the result. An explosion at an ammunition store and in a munitions factory, an accident during the loading of munitions onto a ship and the disaster caused by a submarine's torpedo malfunction are some examples.

The development of Insensitive Munitions (IM) has helped reduce the risks in this area yet further. These munitions reduce the effects of an accident or attack because they react less violently; an IM shell neither explodes nor splinters in a fire or under bullet impact. And since the probability of a mass explosion is eliminated, storage is both safer and cheaper, making it a more feasible option in a relatively densely populated area. IM can also reduce the vulnerability of weapon platforms because a hit would no longer put the whole platform out of commission.

All IM developments will boost the safety of the use, transport and storage of munitions. A number of NATO countries already require all munitions that are purchased to comply with the IM standard, something that can be attained by replacing conventional explosives, such as TNT and CompB, with new explosives such as Plastic Bonded eXplosives. The use of composite cases for rocket engines instead of steel cases can prevent an explosion occurring in the event of an engine fire or fragments getting into the engine. One of the tasks TNO-PML has undertaken is to research today's munitions with a view to upgrading them to match the standard set by IM and examining what the consequences of such a change will have for defence. TNO-PML is also helping to formulate an IM policy.

TNO-PML’s experimental and computer facilities enable the safety and performance of munitions to be tested and the safe recycling and disposal of munitions to be examined. Tests can be performed on the detonation of munitions, munitions components and the response of munitions to threats like fire, bullet impact and sympathetic reaction. Customers include the Dutch government and foreign defence organisations as well as foreign and national companies and research institutes. TNO-PML has built up the knowledge and facilities required for the transition to IM, an investment that can be used and extended through collaboration with partners in the field with a vested interest in its practical application.

Revised calculation models reduce development costs of munitions

Shooting at real targets is the traditional way to establish the effectiveness of types of munitions and weapons, but it is an expensive approach. Weapons developers are now tending to work more and more with vulnerability and lethality models because they are both cost-effective and can quickly reveal whether modifications to the design will improve the effectiveness. TNO-PML develops and uses specialised calculation models to gather this kind of data.

TNO-PML employs both new and traditional approaches to determine the lethality and effectiveness of munitions. An example of this is the testing and evaluation of Frangible FAP and FAPDS mid-calibre munitions using firing tests on simulation targets at its ballistics research laboratory in Ypenburg and on real targets in Switzerland. With subsequent detailed effectiveness calculations for various target models (like BMP, MiG and F-16) under specified operational circumstances, the effectiveness of the munitions was improved quite significantly.

In close collaboration with TNO-PML, the manufacturer is now developing a new generation of FRAP (FRAgmenting Payload) munitions. TNO-PML is not only calculating the munitions impact and effectiveness but is also making proposals to optimise the impact of the FRAP munition. By making smart modifications in the munition properties and calculation models, TNO-PML is able to quickly show whether relatively inexpensive modifications in the munitions design will have any real influence. Finally, a rapid cost-benefit estimate of a design can be made at a very early stage and thus avoid the need for too many experiments. The resulting information is vital to the development of the best munitions at the lowest cost.

Other examples in this area include research into the impact of the new PELE (Projectile with Enhanced Lateral Effectiveness) munitions and research into the effectiveness of combat tanks with new 120 mm HETF (High Explosive Time Fused) munitions.

Our facilities

Besides highly qualified staff with specialised knowledge, the TNO Prins Maurits Laboratory has unique experimental research facilities, including:

- Ballistics laboratory: a ballistics research facility, including a large-calibre firing range with a target bunker, designed and proven to withstand detonations of up to 25 kg of high explosives.

- Tox lab: all activities with toxic or carcinogenic compounds are carried out in a dedicated ‘High Tox’ laboratory, which insures optimum safety for our staff a well as protection of the environment from contamination with hazardous substances.

- Pyrotechnic laboratory: especially designed and constructed for research into energetic materials.

- Rocket test stands: Rocket test facilities for full-scale rocket and ramjet testing.