Defense Systems Division

TPL's Defense Systems Division represents a highly integrated capability in the demilitarization of conventional munitions - from the conduct of Resource Recovery and Reuse (R³) into uses for reclaimed energetic materials, to providing engineering services in conventional munitions demilitarization operations and to the manufacture of commercial products from the reclaimed energetic materials. This systems approach to the solution of a complex problem, i.e., cost effective and environmentally acceptable means of disposing of obsolete munitions, illustrates the philosophy behind TPL's business model-services or products built upon a strong technical base that satisfy a critical niche need.

Energetic Materials R&D

• Defense Energetic Materials Products
• HMX Recovery & Requalification
• Ultrasonication for Explosive Removal
• Magnesium Recovery from Pyrotechnic Munitions

Enhanced Warfighter's Capabilities

• Flashless Powder for Small Arms Ammunition
• Barrel Cladding for Advanced Gun Systems

Energetic Materials R&D

Resource Recovery & Reuse

TPL is an industry leader in the R³ of energetic materials reclaimed from demilitarization processes with a reuse rate overall in excess of 95%. TPL's integrated processing facility converts over 4 million pounds of artillery propellants per year into commercial blasting agents for the mining industries. R³ facilities designed by TPL are being established at the Hawthorne Army Depot, NV and the Crane Army Ammunition Activity, IN.

TPL's expertise in demilitarized materials resource recovery and reuse is providing the military with new options to reutilize valuable energetic materials for weapons applications. These include the recovery of magnesium from pyrotechnic compositions and HMX, an extremely valuable explosive constituent from high performance explosives or propellants.

TPL's innovative use of energetic materials has resulted in the development of two technologies which have profound implications for the US military - the extension of gun barrel performance and life through the application of a refractory metal-explosive cladding process and a unique propellant powder for small arms ammunition which has flashless characteristics.

HMX Recovery & Requalification

TPL has developed a patented process for the recovery of pure HMX from a variety of the energetic material formulations. Demilitarization of obsolete weapons and rocket motors provides TPL with a continuous source of available material for recovery and reuse. The process oxidizes and removes polymeric binders and plasticizers from the formulation and produces a product with extremely low RDX levels. The HMX produced by this process is very pure and does not include any residual polymer or plasticizer. Testing at Los Alamos National Laboratories and the at Indian Head have verified that the material could easily qualify as virgin material for military use with some modification of particle distributions. The extremely low levels of RDX in the recovered HMX from TPL's process makes this material especially well suited to high temperature applications.

A program is currently underway to expand the plant capacity to 600 pounds per batch and improve computer controls and automation. Part of this program includes the verification of performance of recovered HMX in military compositions including PAX-2A, PAX-3 and PBXIH-135.

Ultrasonication for Explosive Removal

TPL has developed a method for the ultrasonic removal of cast energetic materials from munitions. This Phase II SBIR program for RDECOM-ARDEC developed a successful technique and process for the complete removal of all Comp-B from 81mm mortar rounds. An inert substitute was also found that closely simulated for preliminary testing. A pilot plant has been built and assembled for the remote and automated processing of up to six live mortar rounds of various sizes. It has been shown that the cast explosive fill material could be recovered in a granular form that was readily cleared of contaminants and easily cast for reuse in other munitions.

Magnesium Recovery

TPL is engaged in a government supported program to develop a process and build a plant to extract and refine magnesium (Mg) from different obsolete military flares. The objective is to provide a facility to economically demilitarize flares and produce pure Mg for reuse from an environmentally friendly process. The challenge is to design the facility capable of processing the full spectrum of military ballistic flares, with different dimensions and chemical compositions. The production goal is to produce 600 pounds of Mg per shift.

Enhanced Warfighter

Barrel Cladding

TPL has conducted a development program to use recovered/recycled energetic materials to explosively clad Tantalum (Ta) and its alloys to the interior bore of gun barrels to extend their service tube life. In Government tests using the 25mm M242 Bushmaster and developmental M919 ammunition, TPL's clad barrels demonstrated a six to ten fold improvement in resisting bore erosion. The baseline steel barrels were condemned after firing 229 rounds. TPL's Ta-clad barrels were still serviceable when the APG test range ran out of ammunition after 1385 rounds. Other potential military weapon applications include longer range howitzer and tank barrels, medium multi-barrel Gatling and chain gun systems, electro-thermal gun systems, and rail guns.

Flashless Powder

TPL is developing a line of low flash small arms ammunition powders that can be fabricated from demilitarized artillery feed stock propellants. Ammunition loaded with this flashless powder will provide a distinct improvement in combat effectiveness and soldier survivability for close combat, nighttime engagements. The focus of this program is to exploit the low flash characteristics derived from the retardant additives in artillery propellants, while achieving a sufficient ballistic performance to meet ballistic standards for military usage.

The Albuquerque SWAT Team demonstrated the ballistic performance of handgun ammunition. These tests resulted in a 40% reduction in the time to acquire and address a second target. The reduced signature of flashless powder renders the muzzle flash undetected by the naked eye at night at ranges over 50 feet. The overall effect provides the soldier with greater accuracy without exposing himself to visual location and return fire, rendering this propellant ideal for US Special Operations Forces.

TPL, Inc., 3921 Academy Parkway North NE, Albuquerque, NM 87109, 505-344-6744, Fax 505-344-1412

Copyright 2007 TPL, Inc. All rights reserved.