PYROTECHNICS

SYSTEMS DESIGN

1.INTRODUCTION
Pyrotechnic systems perform mission
critical functions in rocket flight by
controlled use of explosive power. They
are:

-Ignition of rocket motors.

-Separation of spent stages.

-Heat shield separation.

-Satellite separation.

-Solar panel & boom deployment.

-Operation of flow control valves of the
propulsion systems in rockets and
satellites.

WORKING PRINCIPLE
Energy contained in explosive charge
is utilized to carry out the desired
function as per design.
Controlled use of explosive POWER
has enabled difficult functions in
aerospace systems to be performed
as per design.

ADVANTAGES

1.High power / weight ratio.

2.High reliability.
3.Simplicity of design.
4.Small / Compact size.
5.Low operating current.
6.Simple circuit.
7.Ability to deliver more energy in a
very short time.

DISADVANTAGES
1.Single shot device and hence NO
functional check is possible before
flight.
2.Pyrotechnic shock can cause
damage to other systems.
3.Presence of explosive material is
not comfortable.
4.Possibilty of inadvertent firing .

PARADOX AND EDICT

Earlier stages of Space Shuttle
progaramme had an Edict that there would
be no pyrotechnic in the vehicle or payload
because they were not reusable.
However, each Shuttle mission had over
400 pyrotechnic components, with some
used in flight and others only for
emergencies.
Such is the importance of pyrotechnics for
aerospace applications and it has become
an inevitable & indispensible technology.

2.EXPLOSIVES

AD 700 : Discovery of black / gun powder.

AD 1000 : Use in weapons of war.
AD 1548 : Use in civilian fields- mining etc.
AD 1848 : Italian professor Ascanio Sobrero
discovered liquid Nitro Glycerin.
Later on, NG was commercialized by
Immanuel Nobel and his son Alfred B.
Nobel.

 This pioneering work led to the

invention of fulminate detonator and
discovery of kiesel ghur, an effective
absorbent of liquid NG.
With this, the science of pyrotechnics
opened up for effective use of explosive
POWER in civil and military fields.
Many compounds like NC, Cordite, TNT,
RDX, HMX were formulated.
Each one of the above has its own
merits and demerits.

 Chemically, explosive process is

Oxidation.
1 kg of TNT gives 4080 kJ of energy.
1 kg of petrol gives 30,000 k J of energy
on combustion.
But the usefulness of explosive is derived
from the speed / rate at which energy is
released rather than the quantity of it.
The search for synthetic dyes resulted in
production of compounds containing one
or more Nitro groups, many of which are
explosives themselves.

 The oxygen for combustion is held in NO2

group.
Such a group may be attached to O/C/ N
atom in the molecule and are called
Nitrate /Nitro / Nitramine respectively.
On appropriate initiation, these compounds
will explode violently.
The molecular structure breaks down on
explosion, leaving momentarily disorganized
mass of atoms.
These, immediately recombine to give
predominantly gaseous products and evolve
considerable amount of heat-Heat of
Explosion.

2.1 Classification/Types
For reliable function, a minimum of two
explosives are used in succession.
1st material is priming explosive and helps
in triggering the 2nd charge.
2nd charge is less sensitive but of high
power output to perform the required work.
Based on the explosive characteristics, the
major classifications are:
(i) Primer/ initiating charges.
(ii) Deflagrating materials/Pyrotechnic
charges
(iii) High explosives.

(i) Primer / initiating charges : have

high degree of sensitivity to initiation
through shock, friction, electric spark
or temperature but not too sensitive.
Examples are: Lead azide, Lead
styphanate.
(ii) Deflagratory materials: undergo
combustion to produce heat & gas.
- These are more stable than primary
charges
and are set off by
initiators to produce combustion
products which perform the work.

- Different forms such as loose

powder, grain, pressed, cast or
extruded charges are used.
- Some burn layer by layer like the
propellant but more rapidly and are
used as gas generator.
- Pressure cartridges are used in
igniters of solid motors, in actuation
devices like valves and thrusters.
- Examples are: NC powder,
Aluminium-ammonium per chlorate
or Boron-potassium nitrate .

(iii) High explosives: when initiated

suitably, dissociates almost
instantaneously to detonate into
other stable compounds to produce
gas & high temperature.
- The fast detonation generates shock
waves and the rate of decomposition
is limited by the velocity at which the
charge can transmit the wave.
- Examples are: RDX, TNT, PETN etc.

3. EXPLOSIVE INITIATORS
An activation energy is to be applied on
the explosive charge to initiate chemical
reaction.
Means of this energy inputs are:
- electrical
- mechanical
- shock wave
- Laser
- semi conductor bridge
- combination of the above.

3.1 Electrical
Electro Explosive Devices ( EED ) are hot
wire initiators and has two types.
- (i) Squibs and Cartridges.
- (ii) Detonators.
- Squib is a thin resistance wire ( 15-100
micron diameter) on heating raises the
temperature of the primer charge.
- Cartridge is an additional charge , placed
adjacent to primer picks up the flash to
produce hot gas.
- Detonators are high explosive devices unlike
squibs & initiate other high explosives.

 Inadvertent firing of electrical initiators can

be caused by maximum induced current
that could reach EED due to the following:
- Test instrumentation.
- RF sources of on-board & ground.
- Parallel power lines.
- Human static discharge.
. Keeping a margin over this estimate, a
safe current(no fire current) is specified for
EEDs.
. Electrical sensitivity of squibs is defined by
means of No fire & All fire limits.

 (ii) Detonators are high explosive devices

unlike squibs and they produce
maximum
brisance.

They have squibs and high explosive

charge
and are used to initiate other
explosives.

4. PYRO MECHANICAL DEVICES

These are used for a variety of
applications in aerospace:
-Staging systems in LV.
- Heat shield jettison / separation in
LV.
- Destruct systems in LV.
- Deployment mechanisms in SC.
- Flow control systems valves; NO /
NC types in both LV and SC.

 Combustion of explosives pressurizes a

piston-cylinder assembly so that piston
movement executes the desired
mechanical function.
This is similar to IC engine but an oneshot engine.
Pyro charge is held in the cartridge and
on actuation pyro gas pressurizes the
piston to do the intended work / function.
Classification of pyrodevices :
- Pyro cutter.
- Pyro valve.
- Pyro thruster.

 In satellites, the common deployment

functions are done for Solar panel, Antenna
and Solar boom.
The solar panels are usually folded and are
tied by steel ropes in launch configuration. In
orbit, at the time of panel deployment, the
rope is cut by pyro cutter thus releasing the
tie and the spring loaded panel is deployed to
its stretched condition.
The solar boom and antenna are folded& held
by bolts during launch. In orbit, when the pyro
cutters cut the bolts, the spring loaded
mechanism releases the boom or antenna to
its deployed position.

4.1.2. Pyrovalves
These are used in fluid flow lines of aerospace
by opening & closing of fluid flow paths.
Two types are generally used. Normally open
(NO) and normally closed (NC).
NO pyro valves have a wedge shaped valve
pistons when forced by pyro gas shears the
already open fluid line & block the flow path.
NC pyro valves have a diaphragm in the line
blocking the flow in pre-fire condition. When
the valve is actuated, the pyro gas pressure
forces the valve piston to shear the diaphragm
enabling fluid flow.
Relative taper between piston & cylinder
enables positive retention in post fire position.

 Pyro valves alone can ensure effective

control; Being leak tight before & after
fire condition and high reliability.
Wide application meeting specific
requirements in liquid propulsion
systems.
In cryogenic systems, numerous pyro
valves are used for safe & reliable
operations.
In spacecraft propulsion systems, pyro
valves are used in apogee kick motors.

4.1.3.Pyrothrusters
These are the simplest of the pyro
devices with ordinary piston-cylinder
arrangement.
On pyro cartridge firing, the pyro gas
forces the piston to do the external
thrusting function .
Thrusting requirements dictate the rate
of pressurization based on which the
pyro charge in the cartridge is selected.
Used for a variety of jettisoning &
unlocking functions and Ball Release
Mechanism (BRM) is one of them.

Applications
External stages like strap-on motors or
external tanks which are attached to
main vehicle body are separated by
explosive bolts or nuts or both.
- ASLV strap-on cases : explosive
bolts.
- PSLV strap-on cases : explosive
nuts.
. Shock and contamination during
operation are the limitations for
sensitive applications.

5. SAFETY AND
ARMING(SAFE/ARM) SYSTEMS

This prevents premature initiation of

pyrotechnic devices used in launch
vehicles thus ensuring safety & reliability.
Inadvertent firing of a device can be
caused due to lightning, stray current and
even static discharge.
These Safe/Arm systems have two stable
positions, one safe and the other arm.
When in safe position, premature firing is
made impossible and in the arm position,
initiation is ensured on receipt of signal.

FIG.20. Safe / Arm System

 Most of the Safe/Arm devices have a

rotor, which holds a transfer charge .
In the safe condition, the transfer charge
is misaligned in the explosive train and
any accidental initiation of donor charge
is not transferred to the acceptor side.
In the arm condition, the transfer charge
is aligned in the explosive train and the
stimulus of the donor charge is
transferred to the acceptor side through
the transfer charge, which actuates the
pyrodevice.

 Safe/Arm devices of different

configurations & operating methods have
been developed and there are versions for
manual as well as remote operation.
These devices usually have additional
features like shorting of the initiator
electrical leads in safe position,
independent locking at safe and arm
positions and visual & remote indication of
safe and arm status.
To attain the required level of confidence
in the device, they are tested & qualified
under extreme environmental conditions.