Energy Technologies facilities

Active Denial System

Kirtland AFB, NM

The technology was originally developed by the Air Force Research Laboratory and matured under the sponsorship of the Department of Defense’s Joint Non-Lethal Weapons Directorate. Approximately $51 million has been invested over the past eleven years. The technology was developed in response to Department of Defense needs for troops to have options short of deadly force. Non-lethal technologies can be used for protection of defense resources, peacekeeping, humanitarian missions and other situations in which the use of lethal force is undesirable. ADS will provide these capabilities close in as well as at longer standoff ranges.

Aerothermodynamic Measurement Laboratory (ATMLab)

Arnold AFB, TN

Battery Laboratory

Port Hueneme, CA

The NFESC Battery Laboratory is used primarily for the testing of silver-zinc batteries, such as Deep Submergence Rescue Vehicle (DSRV) and Deep Submergence Vehicle (DSV) batteries. In tandem with NFESC’s Deep Ocean Simulation Facility (DOSF), silver-zinc batteries containing up to 76 individual cells can be tested to pressures exceeding 5,500 psig, and temperatures ranging from 32 ° F to 70 ° F.

Battery Reclamation Facility

Panama City, FL

Costs to dispose of batteries containing mercury by traditional methods through the Defense Reutilization Marketing Office (DRMO) range upward to $20 per pound. Naval Programs are not charged for the disposal of silver-zinc batteries, but, the potential value of the silver within the batteries is lost when they are simply turned in to the DRMO.

CERL HVAC Test Facility

Vicksburg, MS

The air distribution system has a primary air intake with a mixed air section consisting of mechanically linked outdoor and return air dampers and a separately actuated exhaust damper. The supply fan feeds a single or dual-duct air system (as dictated by the particular system configuration being used). The return air duct is arranged so the return fan can be used or by-passed. Both the supply and return fans are modulated by variable speed drive units. A separate ventilation system contains an outdoor environment simulator (OES) consisting of heating and cooling coils, which permit conditioning of outdoor air to establish desired test conditions. Airflow measurement stations are installed in each primary and branch duct.

Directed Energy Research Center

Picatinny Arsenal, NJ

The Directed Energy Research Center is supplied with 2.5 million volt-amp power developing and testing of advanced energy based systems. Building contains a grounding grid the capability to discharge 1 million amps without damage to equipment and facilities or Picatinny Infrastructure. Two Shielded Rooms are capable of shielding against Low Frequency magnetic fields and High Power Microwaves simultaneously with secure areas allowing real-time Classified Data Processing. There are two Highbay areas for integrating technologies onto mobile platforms. Equipment and facilities include: Anechoic Chamber (EM and RF Shielded), High Bay with Crane, Ultra Short Pulse Laser Laboratory Annex, and laboratory work benches. This World Class High power Laboratory is capable of providing High Voltage and High current requirements. The Directed Energy Facility integrates specialized diagnostics and data acquisition equipment with capability of measuring and processing high power RF systems being developed for the future Warfighter. High Voltage capabilities Up to 1 million Volts with Directed Energy Technologies include:

Energetic Materials Analysis Laboratory

Picatinny Arsenal, NJ

The Energetic Materials Analysis Laboratory is a recognized leader in the field of energetic materials chemistry and provides support to the tri-services, other government agencies (FBI, DEA), approved foreign governments, academia, and private industry through analysis and testing in support of development of new ammunition, qualification of energetic material used in DoD munitions, life-cycle testing of fielded munitions, development of demilitarization and disposal processes, and investigations of field malfunctions. The extensive test and evaluation capabilities of the lab play a key role in ensuring material quality and ordnance reliability. State of the art laboratories and instrumentation are used for the characterization and assay of new explosive compounds, MIL-STD, NAVSEAS, and STANAG qualification, exploitation of foreign ammunition, compatibility of energetic and ammunition components, methods development, and investigations of manufacturing deficiencies, malfunctions, accidents, bombings, and criminal fraud. The laboratory consists of a physical properties laboratory, a thermal properties laboratory, a metals laboratory, a wet chemistry laboratory, and an instrumental laboratory for both organic and inorganic analyses. Instruments include GC-MS, DSC, TGA, FTIR, ICP-AES, Atomic Absorption Spectroscopy, Reaction Rate Calorimeter, Accelerated Rate Calorimetry, High Performance Liquid Chromatography, Karl Fischer Automated Titrator, and Ion Chromatography. With our qualified staff of chemists, scientists, and technicians, EMAL can provide a wide variety of on-site sampling and testing services. Whether the situation calls for using a state-of-the-art portable instrumentation or downloading and obtaining a representative sample from a munition, EMAL possesses the personnel, equipment and expertise to perform routine or highly specialized sampling and testing services. With more than 70 years of experience in responding to emergencies involving energetic materials, EMAL has the capability of identifying unknown substances in hours not days.

Energetic Materials Machining Facility

Picatinny Arsenal, NJ

This building is currently on line with 8 bays that house numerous machine tools for both contact and remote machining of energetic materials. Current upgrades include a CNC lathe, a CMM Measuring machine and most recent a CNC milling machine installed last week. There are Conventional lathes, Milling machine, band saw and drilling machines. This facility is very active and has been on line and providing quality energetic machining support to our staff for many years and the building itself although quite old is often used to showcase our capabilities within the group.

Energetics Conditioning Facility

Picatinny Arsenal, NJ

The Energetics Conditioning Facility is used for long term and short term aging studies of energetic materials. The facility has 10 conditioning chambers of which 2 are equipped with humidity control, 1 with refrigeration, and 1 at ambient conditions. Temperature control and recording are available in all 10 chambers. The facility can accommodate up to 1,000 pounds of energetic material per study.

Energetics Laboratory Facilities

Picatinny Arsenal, NJ

These energetic materials laboratories are equipped with explosion proof hoods with blow out walls for added safety, that are certified for safe handling of primary as well as secondary high explosives. Modern instrumentation for thorough analysis and characterization of new energetic materials is available. Analytical techniques available on site include high field nuclear magnetic resonance spectrometry, Fourier transform infrared spectrometry, high performance liquid chromatography, gas chromatography coupled with mass spectroscopy, atomic absorption spectrometry and UV-visible spectrometry, scanning electron microscope/transmission electron microscope. Equipment for process development and scale-up of energetic materials is available including jacketed reactor vessels and programmable heating and cooling circulators. Analysis of thermal properties of new materials is carried out using differential scanning calorimetry and thermal gravimetric analysis. Computational facilities include various personal computers and workstations and software for advanced molecular modeling and prediction of energetic performance characteristics of new materials. Availability of these capabilities under one roof make these laboratories a premier site for the research, design, development and scale-up of new energetic materials for the next generation weapon systems.

Energetics Rheology Laboratory

Picatinny Arsenal, NJ

The Energetics Rheology Laboratory houses a variety of instruments and equipment for the characterization of energetic materials, which include propellants, explosives, pyrotechnics, precursor materials and non-energetic materials such as epoxies, composites and polymeric resins. All instruments are remotely controlled from a centralized control room via CCD surveillance cameras and computerized monitoring systems. The ERL is used to conduct various experiments and analyses of energetic and non-energetic materials. The ERL uses specialized software and data analyses programs, making the ERL a technically competent and unique site for performing energetic materials characterizations

Energy and Power Source

Crane, IN

Provides comprehensive life cycle management functions to provide safe, reliable and effective batteries and other energy storage and power source devices. Includes engineering expertise and facilities to provide industrial base support services for batteries and other energy storage and transfer devices (fuel cells, uninterrupted power supplies, solar cells, power supplies and ancillary equipment). Services include: product improvement, requirements definition, design, development, prototyping and limited production, acquisition and acquisition engineering, standardization, test and evaluation, safety certification of high energy battery systems including lithium technology, technology evaluation and insertion, production engineering, in-service engineering, obsolescence management, maintenance, Fleet training and system retirement.

Fuel Cell Lab

Philadelphia, PA

Up to Approximately 500 kW Power Level. Hydrogen Fuel Supply. Compressed Air supply. Inert Gas Supply. Cooling Water Supply.

Fuel Cell Laboratory

West Bethesda, MD

This laboratory is devoted to the test and evaluation of fuel cell power plants for naval surface and undersea applications. It consists of a 900 square foot NFPA Class 1 Division 1 Group B hazardous-atmosphere rated test chamber, with an adjacent assembly/checkout laboratory and a test control room. The laboratory is designed for testing up to 2.5 megawatts of power generated from fuel cells and for interconnection with nearby electrical or mechanical laboratories to form an integrated system. Additional supporting facilities include 2000 square foot outside storage, NFPA Class C hazardous-atmosphere rated fume hoods, and reactant gas storage facilities. Dedicated computer-controlled instrumentation, including a gas chromatograph and on-line gas analyzers, and video recording equipment are available for testing fuel cells and fuel-reforming hardware.

Gamble II

Washington, DC

Generator Test Facility

Aberdeen Proving Ground, MD

Hawk

Washington, DC

High Energy Propellant Formulation Facility

Picatinny Arsenal, NJ

The HEPFF pilot plant is equipped with various mixers, extrusion presses, roll mills, and propellant finishing equipment to produce both solvent and solventless propellants, including composite propellants based on energetic thermo-plastic elastomers and high energy fillers. Characterization and testing capabilities include a rheology laboratory for energetic materials, burning rate by closed bomb and strand burner, calorimetry and thermal analysis facilities, and physical properties measurement, as well as subscale interior ballistic performance determination, and energetic sensitivity testing (critical diameter, shock initiation). The HEPFF will provide a comprehensive site for the continuation of ARDEC's role in propellant development, and a focal point for preserving and advancing the knowledge base necessary for efficient and productive future propellant development.

High-Enthalpy Arc-Heated Facilities

Arnold AFB, TN

High-Power Microwaves

Kirtland AFB, NM

The general public is familiar with the technology as it applies to household microwave ovens that use this form of energy to penetrate and cook food. Whereas a typical microwave oven generates less than 1,500 watts of power, the Division is working with equipment that can generate millions of

Microwave Technologies

Crane, IN

Provides comprehensive life cycle management functions to provide safe, reliable and effective microwave technologies components, which include Solid State and Vacuum Electron (Microwave Tube) devices, for military Electronic Warfare, Sensor, and Communication systems. Includes research, design, acquisition engineering, procurement, testing and evaluation, qualification, failure analysis, sustainment, in service engineering, and engineering expertise necessary to develop, improve, and sustain military Electronic Warfare, Sensor, and Communication systems. Services provided include RDT&E;, AE and Sustainment of microwave technologies components utilizing the Systems Engineering process; Executive Agent for DOD Microwave Tubes; Navy Radar Microwave Tube acquisition engineering and in service engineering, including Fleet/ship problem investigations, system requirements determination, performance based logistics management, reliability and maintainability analysis, manufacturing audits, organic qualification testing of microwave technologies components, and specialized microwave laboratory test equipment design.

Mobile Generator Test System

Aberdeen Proving Ground, MD

Power Electronics Lab

Philadelphia, PA

110, 208, 220, 480 VAC 60 Hz electrical power to supply equipment under test. Up to 200 A @ 480 VAC, 60 Hz. Various DC supplies available for equipment under test. Control/drive circuit prototyping hardware. Solder/de-solder stations. High power conversion assembly and test equipment. Power semiconductor device characterization equipment with access to electrical sources and loads via interface with Electrical Systems R&D; Lab B.

Power Generation Test and Evaluation Facility

West Bethesda, MD

The Power Generation Test and Evaluation Facility consists of the CG-47 SSGTG Test Site, the Electrical Test Site and the Integrated Power System (IPS) Land Based Engineering Site. The CG-47 SSGTG Test Site provides the dual capability of testing a CG-47/DDG-51 Class Gas Turbine Generator (SSGTG) set and 60Hz, 400Hz, and Direct Current electrical distribution system and components for the entire fleet. The Electrical Test Site is utilized for testing shipboard electrical power generation, distribution, conversion and control equipment for conformance to applicable specifications, suitability for intended use, reliability and maintainability. The Integrated Power System Land Based Engineering Site has been constructed to test the IPS system architecture and operational performance characteristics to determine the system viability as a future propulsion and ship service system.

Pulse Power Lab

Picatinny Arsenal, NJ

The Pulse Power Laboratory has 2.5 million volt-amp power supply for testing of Advanced Energy systems (High Power Systems). Building is also specially grounded with the capability to discharge 1 million amps without damage to equipment and facilities. Two Shielded Rooms are capable of shielding against Low Frequency magnetic fields and High Power Microwaves simultaneously with secure areas allowing real-time Classified Data Processing. Two Highbays for integrating technologies onto mobile platforms. Equipment and facilities include: Anechoic Chamber (EM and RF Shielded), High Bay with Crane, 6 Mega Joule Capacitor Bank, Ultra Short Pulse Laser Laboratory Annex, and laboratory work benches. This World Class High power Laboratory is capable of providing High Voltage and High current requirements. The unique capabilities of this facility are crucial in the development of Directed Energy Weapon Systems and Non-conventional / Directed energy Technologies. Possible applications include In-Theatre Force Protection, Homeland Defense and Facility Protection Systems. It integrates specialized diagnostics and data acquisition assembled for measuring and processing the ultrawideband and high power systems being developed for the future warfighter. High Voltage capabilities Up to 1 million Volts with applications to include: High Power Microwave systems Laser weapon systems High voltage components High Current capabilities 100,000 " 500,000 Amps @ 20,000 "30,000 volts Test Components for Pulse Forming Networks Kinetic Energy Weapons Electromagnetic Propulsion Guns Electro Thermo Chemical Guns

Small Engine RDT&E; Facility

Philadelphia, PA

Perform research, development, test and evaluation of advanced technologies to increase power and efficiency and reduce emissions of small engines and power generation systems.

Wind Tunnel Facility

Picatinny Arsenal, NJ

This ARDEC facility consists of subsonic, transonic, and supersonic wind tunnels to acquire aerodynamic data. Full-scale and sub-scale models of munitions are fitted with sensitive laboratory instruments and mounted in the wind tunnels to measure free-flight aerodynamic characteristics such as stability, drag, spin rates, fuze arming, etc. The facility can accommodate munitions of all types, from small arms to large caliber anti-tank, mortar, and artillery rounds. In most cases the items can be tested at tactical flight conditions.