A combination of innovative steel pipe continuous flow casting and heat treating will be combined to produce lower cost, a) general purpose (Mk 80 series), and b) deeper penetration (BLU-109/B [BLU-137B upgrade] bombs. Additionally, these steel manufacturing processes may also enable the production of lower cost c) high fragmentation, area attack weapons. This proposed flexible and scalable manufacturing process will allow the use of low alloy steels (ductile irons) to be transformed into viable bomb body steels through the proposed innovative continuous flow casting process, followed by novel heat treat and quenching process. In summary, the continuous flow casting of seamless ductile iron pipes will produce , defect free pipes near the desired final dimensions of the bomb body. Since these pipes are made from ductile iron, traditional fabrication processes will be implemented to readily machine the near net shape bomb bodies to the desired outer-mold lines and mass properties. Once machined, the novel heat treat and quenching process will be implemented to transform the ductile irons into a steel with the desired mechanical requirements that conform to the Technical Data Packages of both the general purpose and deep penetration bomb bodies.
Benefit: The resultant low cost, bomb body casings will be compatible with both JDAM tail kits and especially with current transportation systems. These continuous flow cast pipes can be readily tailored for production in multiple diameters and wall thicknesses. These pipes are currently produced in lengths of ~ 18ft with varying wall thicknesses from 0.25 inches to 1.75 inches without seams and without defects. The Ductile Iron alloy composition will be tailored to achieve the desired mechanical properties after the innovative heat treating and quenching process. This rapid quenching known as Intensive Quenching (IQ) results in beneficial properties which result in parts with greater strength, high hardness, improved elongation and low distortion from the same quench process. Further, the parts exhibit superior toughness even at low temperatures. Finally, the process is designed for integration into current metal fabrication lines which will further reduce manufacturing and shipping costs of the bomb bodies.
Keywords: Intensive Quenching (IQ), Intensive Quenching (IQ), Lean Manufacturing, ductile iron, Mk 80 Series, flow forming, continuous flow casting, BLU-109/B, bomb bodies
