MONTHLY PROGRESS REPORT - ENGINEERING PROGRAM FOR THE DEVELOPMENT OF A LIGHTWEIGHT ANTI-TANK ROCKET

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03642A000800060010-6
• Release Decision: RIFPUB
• Original Classification: S
• Document Page Count: 28
• Document Creation Date: December 27, 2016
• Document Release Date: August 8, 2011
• Sequence Number: 10
• Publication Date: December 1, 1958
• Content Type: REPORT

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HESSE-EASTERN
EVERETT, MASS.
REPORT NO. 12-8-50G-1
MONTHLY PROGRESS REPORT
ENGINEERING PROGRAM FOR THE
DEVELOPMENT OF A LIGHTWEIGHT
MONTH OF DECEMBER 1958
CONTRACT NO. RD-142
OXI3?lI;DKxW)M"90M X
lRKMXI X C t XX?X
This document contains information affecting the
national defense of the United States within the
meaning of the Espionage Laws, Title 18, U. S. C.,
Sections 793 and 794. The transmission or the
revelation of its contents in any manner to an
unauthorized person is prohibited by law.
Fe e0so
/VY
7"C' 717
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H E S S E - E A S T E R N D I V I S I O N
FLIGHTEX FABRICS, INC.
PROGRESS REPORT # 16
ENGINEERING PROGRAM FOR THE DEVELOPMENT
OF A LIGHTWEIGHT ANTI-TANK ROCKET
PREPARED BY APPROVED Blfa, _" .r ~r
Thomas Forman Charles B. Weeks
Project Engineer General Manager
SUBMITTED BY: HESSE-EASTERN DIVISION
FLIGHTEX FABRICS, INC.
EVERETT, MASSACHUSETTS
SECRET
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WORK DONE DURING THE MONTH OF DECEMBER 1958
SYSTEM EVALUATION PROGRAM
Seven systems for a demonstration for your agency have been as-
sembled and picked up. Accuracy tests, ignition tests, and functioning
tests with Model No. 3 fuze have been conducted. Assembly tools are in the
process of being made, and methods of assembling the system are being de-
vised.
MOTOR DEVELOPMENT PROGRAM
Accuracy and Ignition
An accuracy test at 50 yards was conducted 4 December 1958.
Photograph No. 144 shows the results. The following is a tabulation of
this test. A target was placed at 50 meters from the launcher. The laun-
cher elevation was not changed throughout the test. The sights were used
and aimed at the center of the group on the target as shown on Photograph
No. 144. Modified Igniters (see Photograph No. 145) with polyethylene
wrapped around were used on all rounds:
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R T
SEC
Round No. Temperature Vel. F/S Type Motor
392
-20
Extruded
Very long ignition
delay (more than one
second caused prob-
ably by throat con-
tour in motor)
393
-20
286
Machined
No comments
394
-20
285
Machined
No comments
395
-20
286
Machined
No comments
396
-20
286
Machined
No comments
397
1120
308
Machined
No comments
398
020
290
Extruded
No comments
399
1-120
No camera
Machined
No comments
400
f120
No camera
Machined
No comments
401
f120
No camera
Machined
No comments
403
Amb.
305
Machined
Round assembled with
Lorne before firing
With the exception of Round No. 392, this test confirms previous
tests as far as interior and exterior ballistics of the round when used at
a range of 50 meters are concerned.
Extruded motors had been received from the Harvey Aluminum Company
only one day before the test. Two motors were pressure tested at 10,000 psi
and used In this test. When inspecting the motors, some discrepancies in
the throat configuration were found. This results in some difficulties
with the igniter properly clicking into place. See Photograph Nos. 146 and
147. It is possible that this condition caused the long ignition delay for
the following reason:
SEC RE T
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if the Igniter assembly is not properly held near the throat, the
impact of the firing pin may push It forward into the motor body, and this
may result in a very severe loss of pressure before the burning gases in
the motor body push the igniter back into position and close off the end of
the motor, thus allowing the necessary pressure build-up to spit the Igniter
out and start propulsion of the rocket. This initial pressure loss would
result In a long time delay and In lack of thrust, i.e., the low flight of
the rocket (Round No. 392).
Since Insufficient information was available on the Harvey motors,
machined motors were supplied your agency for the demonstration. Eighteen
more rounds were fired with extruded motors in fuze tests, and it was found
that all the rockets operated satisfactorily except Round No. 413 which
was fired at ambient temperature and also experienced a long ignition delay.
The discrepancies between the drawings and the throat configura-
tion were pointed out to Harvey Aluminum Company who have made a change in
their tooling and have since produced motors with a better throat configura-
tion.
Two shipments of 29 and 20 motor bodies have been received. The
second shipment contained the corrected throat configuration and improved
physical characteristics. The burst strength of the latest motors received
from Harvey Aluminum is 15,000 psi. The motors yield at about 14,800 psi.
A permanent set at 11,000 psi is experienced with the first batch of the
29 motors. Changes in the extrusion process have resulted in an improve-
ment of the physical characteristics so that no permanent set is experi-
enced with any motors up to 11,000 psi. However, two batches of motors
FC 7
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will be delivered by Harvey Aluminum, one marked "A" and the other marked
"B". Batch "A" will take a permanent set of .0005" at a hydrostatic pres-
sure of 12,000 psi. Batch "B" will not take a permanent set at this pres-
sure.
it is planned to conduct tests with loose propellant and broken-
up propellant in order to determine the safety of the motor bodies under
dynamic conditions. As soon as these tests are evaluated and sufficient
numbers of rockets fired without failures, shoulder firing will be conduc-
ted.
Since ignition on the test with Round Nos. 392 through 403 has
been satisfactory at high and low temperatures, it was decided to conduct
one more test and try out the same igniter configuration except for the
method of closing off the open end of the igniter. The igniter closure
with the snap-in ring will be used. See Photograph No. 145. This would
facilitate assembly of the igniters and therefore reduce the cost of the
systems by an appreciable amount. It would also improve the water tight-
ness. It is felt that the igniter configuration is not going to cause any
problems in actual shoulder firing as long as only small portions of igni-
ter (or no igniter parts) are left in the motor.
Propellant
The extruded propellant was received late in December, and the
time-pressure curves will be obtained the first part of January and flight
tests conducted to check out the characteristics of the extruded propellant
versus the propellant machined on the 0. D. as used until now.
5L'ECL\I T
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WARHEAD DEVELOPMENT PROGRAM
Ten warheads from Eastern Tool & Mfg. Company were poured at the
Hesse-Eastern Division Range in order to supply heads for the demonstration.
Three of these heads were used in a dynamic penetration test conducted on
II December 1958. Two rounds penetrated the 6" target, and one did not pene-
trate the 6" target. The heads from Universal Match Corporation were re-
ceived later in December. In examining the densities achieved in our pour-
ing and in theirs, there appears to be some question as to the accuracy of
the measurements taken at Universal Match Corporation and the method in
which the measurements are obtained. However, the discrepancy in densities
between our pouring and theirs Is extremely small. The booster and fuze
cavity configuration in the heads loaded by Universal Match Corporation Is
extremely unsatisfactory. The booster cavity is oversize and is as much as
1/8" off center. The level of the charge measured from the rear of the head
is too high. This means that it would be impossible to assemble fuzes with-
out machining the heads.
The remaining heads from Eastern Tool & Mfg. Company have been
shipped to the Universal Match Corporation and a letter sent to them request-
ing an improvement In the pouring configuration. A copy of this letter is
enclosed in the appendix.
Preparations are under way to conduct a dynamic penetration test
In which photographs of the rocket hitting the target will be obtained so
that the actual crush-up can be determined. It is expected that these
tests will be conducted In January. Some difficulties have arisen in this
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regard because of availability of fuze parts. This will be discussed in
the fuze section. it is also planned to conduct dynamic penetration tests
against stacks of 11/2" thick armor in order to get an accurate indication
of penetration. Arrangements are being made with Mr. Kesler at Aberdeen
Proving Ground to obtain some plate for this purpose.
FUZE DEVELOPMENT PROGRAM
Due to unavailability of parts, no static or dynamic fuze testing
with fuze Model No. 4 was conducted in December. A drop fixture has been
designed and placed in manufacture. This fixture will make it possible to
drop the fuze in a number of different orientations and determine the mini-
mum angle of incidence at which the fuze will function, It must be borne
in mind that such a fixture does not completely simulate dynamic conditions
but that it gives merely an indication of the expected functioning of the
fuze in this respect.
At a conference late in November it was decided to shift the em-
phasis from fuze Model No. 4 to fuze Model No. 3. This shift was further
stressed in a letter received from your agency on 23 December 1958. The 20
sets of components for fuze Model No. 4 will be assembled and tested, and a
decision was reached not to order large quantities of fuze Model No. 3 un-
til this test has been conducted and evaluated. Eleven Model No. 3 fuzes
were assembled and checked out for functioning dynamically partly at our
Range and partly at the demonstration conducted by your agency. All fuzes
tested at our Range functioned upon impact. We understand that one fuze
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supplied with the HEAT rounds for the demonstration did not function, it
is possible that the configuration of the Comp B load in the head allowed
the fuze too much play, and this induced malfunction of the safety mechanism.
in addition, two fuze tests were conducted on 22 December and
23 December with fuze Model No. 3 for functioning under graze conditions
and for functioning at -200F:
FUZE TEST - 22 December 1958
Round Nos. 413 through 420
Ambient Temperature
No camera records taken
Round No.
Fuze Function
Comments
413
OK on second impact
Long ignition delay
414
OK on first impact
415
OK on second impact
416
OK on first impact
417
OK on third impact
418
OK on second impact
419
OK on second impact
420
OK on second impact
The rounds are fired in such a way as to hit the ground at a dis-
tance of approximately 70 yards from the launcher. In the case of this
test the surface contacted by the round was hard snow, and the angle of ob-
liquity as evidenced by the marks on ogive and head body was between 10 and 00.
SC JT
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in evaluating this test, it may be stated that properly function-
ing Model No. 3 fuzes show indications of being reasonably graze sensitive,
but that further tests to determine the actual minimum angle of obliquity
required will have to be conducted. Another fuze test was conducted on
23 December 1958:
FUZE TEST - 23 December 1958
Round Nos. 421 through 430
-20 Temperature
No camera records taken
Round No. _ _ _ Ve l . F/S
421 300 (?)
423 424 290
425 ---
304 (? )
295
286
430 290
F_uze Function
Partly armed
Did not function on
graze which was very
light. Was dropped
6" - functioned.
Did not set back.
Did not latch.
in evaluating the results of this test, it appears that some
S C [j
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functioning problems still exist at the cold temperature. In examining the
rotor spring of Round No. 421, It was found that due to the method of an-
choring the rotor spring in the rotor shaft a certain amount of torque may
be lost if the two ends of the spring are not quite In line. In examining
the spring in question, this seems to have been the case. The spring drawing
was therefore changed, and the orientation of the hole which Is used to an-
chor the torque spring In the rotor shaft was moved so as to produce more
stored-up energy in the torque spring under all tolerance conditions. Tests
were conducted statically with fuzes at temperatures varying from -10? to
-44?. it was found that if the torque spring is wound up properly no func-
tioning troubles exist at those temperature extremes.
Round No. 422 did not function on graze. This round hit the
ground at an extremely flat angle of obliquity, and it is entirely possible
that the only type of surface contacted by the round was snow. However,
more tests at the cold temperature will have to be conducted in order to
test whether any differences exist in functioning between hot, cold, and
ambient temperatures. This can be done statically using the new drop fix-
ture which is being made.
Round No. 429 failed to set back. The cause for this Is being
Investigated, and no conclusion has been reached at the present time. A
new firing pin spring has been ordered which will require a slightly smaller
force to compress when setting back. An investigation was conducted to
test the clearances between the fuze housing and the Inertia ele-
ment change under cold conditions. The decrease In clearance turned out to
be less than .0002" at -40?F. No differences could be found at -20?. The
c r VT
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SEC
ET
remaining seven complete sets of fuze parts will be used to conduct a test
to establish the angle of incidence required in order to function fuze
Model No. 3. As soon as the test with Model No. 4 has been conducted, addi-
tional components will be ordered for fuze Model No. 3. Complete sets of
prints on Model No. 3 have been sent out to a number of suppliers for pric-
ing on quantities of 300, 500 and 1,000.
The lock spring has been redesigned in order to achieve smoother
operation and to reduce the possibility of malfunctions. The lock springs
are being cadmium plated and heat treated after plating in order to prevent
any possibility of embrittlement. Until now, lock springs have been protec-
ted by a phosphate rust preventing treatment. Some rust is evident on lock
springs which have been in storage for over half a year. The cadmium should
eliminate this problem. The cadmium plate will also give a soapy and
smoother surface which should reduce the friction between the lock spring
and the fuze housing.
LAUNCHER DEVELOPMENT PROGRAM
Eighty per cent of the final components of the launcher have been
received, and a program of tooling up for assembly has been started. A
number of assembly tools have been made, and a preliminary assembly procedure
has been established. Photograph Nos. 149 through 155 show the tooling and
the steps used in assembling the launcher. All launchers tested at our
Range during November have continued to work satisfactory. We understand
that one assembly used during the demonstration did not fire. Different
S E RET
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possibilities which might have caused this malfunction have been investiga-
ted without any result, and since sufficiently detailed information about
this malfunction is not available, it appears that nothing more can be done
about it. More work was done on igniters, and the following is a tabulation
of Round Nos. 421 through 430 which used the igniter configuration shown in
Photograph No.145, right side:
Round No. Herat ton of Igniter
421 Heavy erosion. Small part of
igniter In motor.
422 Small amount of erosion.
423 Small amount of erosion.
424 Small amount of erosion.
425 Heavy erosion. No igniter parts.
426 Light erosion. No igniter parts.
427 Heavy erosion. Small particles o
Igniter in motor.
428 Light erosion. No igniter parts.
429 Light erosion. No igniter parts.
430 Light erosion. No igniter parts.
in evaluating these results, the following has to be stated:
The velocities of the round seem consistent. Round Nos. 421 and
show faint timing marks on the motion picture record, and the velocities
not quite conclusive on those rounds. The motors used were Harvey ex-
truslons and not hard anodized which explains most of the erosion.
it does
not appear that the small particles of igniter have any particular effect on
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the behavior of the round nor can it be expected that any of the parts
could hurt the gunner since all igniter parts are expelled long before the
round reaches the launcher. Further tests will provide additional data on
this subject.. If necessary, it would be possible to revert to the wrap-
around polyethylene method of loading the igniter. A small amount of trouble
in round performance would, however, be preferable to this since it is not
as good and clear an assembly as the assembly with the cap.
Evaluated vs. Costs Expended for the Month:
December: $11,580.56 P~~
Charles B. Weeks
General Manager
Thomas Forman
Project Engineer
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31 December 1958
Ref : 50G
Universal Match Corporation
Crab Orchard Plant
P. 0. Box 130
Marion, Illinois
Attention: Mr. Wilbur Cox
-Assistant Manager
This is to advise you that the remaining heads from Eastern Tool Mfg.
Company are on their way to you for loading. We wish to make the following
comments:
The cavity for the fuze and booster as shown on our loading Drawing
No. B8428 was not to print in the heads which we received from you. It will be
necessary to stick closely to this drawing and may therefore be advisable to cut
down on the size of the funnel considerably to allow for additional explosive to
be poured in the cavity and to subsequently ream out the cavity in order to con-
form to the drawing. Please advise if you cannot do this, in which case we will
have to change the procedure and will have to ask you to load higher than indi-
cated on the drawing. This would necessitate the reaming operation to be performed
at our Range. We world prefer if you could do the complete job.
Hoping to hear from you very soon and wishing you a Happy New Year.
Yours very truly,
HESSE-EASTERN DIVISION
FLIGHTEX FABRICS,.INC.
Thomas Forman
Project Engineer
TF/mml
'F (r PT
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PHOTOGRAPHS
Photograph No. 144
Accuracy Test December 4, 1958
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Photograph No. 145
Igniters Left Modified Igniter Right Igniter as Molded
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aJL.`rlXi. I
i
Photograph No. 146
Harvey extruded motor showing unsatisfactory
fit of igniter. Incorrectly machined angle
of expansion cone.produces too great a land
In transition area between throat and expan-
sion cone.
~ t.
Rio-
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Photograph No. 147
Cross-section Through Correctly, Machined
Motor Showing Satisfactory Fit of Igniter
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Photograph No. 148
Launcher Components Before Final assembly
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Photograph No. 149
Rivet Squeezer Assembling Trigger Handle
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Photograph Nose 150, 151
Trigger Housing Being A$sembled jo Linkage
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Photograph No. 152
Assembling Rear Sight and Fastener
OUT
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Photograph,No. 153
Locating Trigger Linkage on Launcher Tube
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Photograph . 154
Over-all View of Fingal Assembly Jig
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Photograph No.1155
Rivet Clinching on Fina~ Assembi'y.
Three sets of anvils in rivet clip
cher are used to assemble compI9te
system.
S MO
-Ll
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