Dynamics of Flash Tube Seals in 30-mm Ammunition 

by Stephen L. Howard 

ARL-TR-3211 May 2004 

Approved for public release; distribution is unlimited. 
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Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5066 

ARL-TR-3211 May 2004 

Dynamics of Flash Tube Seals in 30-mm Ammunition 

Stephen L. Howard 

Weapons and Materials Research Directorate, ARL 

Approved for public release; distribution is unlimited. 
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May 2004 

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5a. CONTRACT NUMBER 

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4. TITLE AND SUBTITLE 

Dynamics of Flash Tube Seals in 30-mm Ammunition 

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5d. PROJECT NUMBER 

611102.H67 

5e. TASK NUMBER 

6. AUTHOR(S) 

Stephen L. Howard 

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U.S. Army Research Laboratory 

ATTN: AMSRD-ARL-WM-BD 

Aberdeen Proving Ground, MD 21005-5066 

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ARL-TR-3211 

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EQBRD, Industrial Ecology Center, RDECOM-ARDEC 

ATTN: AMSTA-AR-WET 

Picatinny Arsenal, NJ 07806-5000 

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Approved for public release; distribution is unlimited. 

13. SUPPLEMENTARY NOTES 

14. ABSTRACT 

Certain 30-mm ammunition use a flash tube to augment the primer and to provide an ignition source for the propellant. The 

flash tube must provide abundant hot gases/particles and pressurize the propellant bed sufficiently so that the initial burn rate of 

the propellant is high enough to propel the projectile to the muzzle within the few milliseconds that constitute the action time of 

the cannon. Rupture of the seal at differing rupture pressures was shown to affect the initial pressure in the chamber enclosing 

the propellant bed, as well as the amount of burning particles released into the bed. 

15. SUBJECT TERMS

ignition studies, laser ignition, black powder, medium-caliber gun, flash tube, 30-mm ammunition 

16. SECURITY CLASSIFICATION OF: 

19a. NAME OF RESPONSIBLE PERSON

Stephen L. Howard 

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iii

Contents 

List of Figures iv 

Acknowledgments v 

1. Introduction 1 

2. Experimental 2 

3. Results and Discussion 2 

4. Summary 9 

5. References 10 

Distribution List 11 
iv

List of Figures 

Figure 1. Schematic of breech end of a 30-mm round....................................................................1 

Figure 2. Schematic of flash tube used in tests...............................................................................1 

Figure 3. Simplified schematic of open air fixture to obtain the dynamic rupture pressure of 

a flash tube seal..........................................................................................................................3 

Figure 4. Simplified schematic of fixture to simulate the early-phase burning in 30-mm 

ammunition. ...............................................................................................................................3 

Figure 5. Pressure-time histories of interior of flash tube using selected seal materials................4 

Figure 6. Frames from high-speed video after seal rupture into open air.......................................5 

Figure 7. Photograph of original black powder particles................................................................6 

Figure 8. Photograph of recovered black powder particles from test with Viaktin........................6 

Figure 9. Pressure-time history of rupture of a good nitrocellulose seal in the 30-mm 

simulator. ...................................................................................................................................7 

Figure 10. Pressure-time history of rupture of simulated damaged seal in the 30-mm 

simulator. ...................................................................................................................................8 

Figure 11. Side-by-side comparison of a good and a simulated damaged seal in the 30-mm 

simulator. ...................................................................................................................................8 
v

Acknowledgments 

This work was supported by the U.S. Army Environmental Quality Basic Research and 

Development (EQBRD) Program. The EQBRD program is managed through the Industrial 

Ecology Center at Picatinny Arsenal, NJ. Many thanks are also extended to Dr. Richard Beyer 

of the U.S. Army Research Laboratory. The following companies are also thanked for providing 

samples of sealants: 

Solutia, St. Louis, MO, USA 

Star brite, Ft. Lauderdale, FL, USA 

Sartomer Company, Chester, PA, USA 

Gelest, Inc., Morrisville, PA, USA 

Corrotherm, Inc., Feasterville, PA, USA 

General Electric Company, Waterford, NY, USA 

Amsterdam Colorworks, Brooklyn, NY, USA 

Ciba Specialty Chemicals, Tarrytown, NY, USA 
vi

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1

1. Introduction

Various 30-mm ammunition use a flash tube (figures 1 and 2) to augment the ignition stimulus of 

the primer and to provide an ignition source for the propellant bed in each round. The flash tube 

must be fast acting, provide abundant hot gases/particles, and increase the pressure in the 

propellant bed sufficiently so that the initial burn rate of the propellant in the bed is high enough 

to propel the projectile to the muzzle within the few milliseconds that constitute the action time 

of the cannon. 

Figure 1. Schematic of breech end of a 30-mm round. 

Figure 2. Schematic of flash tube used in tests. 
2

The lacquer seal (1) on the output end of the flash tube is thought by some to do more than just 

keep the black powder in the flash tube. It should be sufficiently strong so that the primer output 

remains in the flash tube until the black powder is ignited and combustion products from the 

black powder have built up enough pressure and hot-particle density. When it does rupture, the 

pressure released, with the accompanying gas flow, should be sufficiently high to increase the 

pressure in the propellant bed so that the initial burning rate of the propellant is high enough to 

complete the ballistic cycle in the time required. A previous study (2) of the rupture pressure of 

the flash tube lacquer seal at up to rupture pressures of 78 MPa indicated that significant gas 

generation would be achieved before the flash tube vented into the main propellant bed. Gas 

flow at these pressures is expected to play a significant role in the ignition of the main propellant 

charge and rapid functioning of the round. However, that study only examined the flash tube 

venting into open air. This study also examines the use of the flash tube in an inert propellant 

bed to simulate actual functioning of the flash tube. 

2. Experimental 

The experiments were conducted on two test fixtures at the U.S. Army Research Laboratory 

(ARL) at Aberdeen Proving Ground, MD, USA. Figure 3 shows a simplified schematic of a 

fixture to test the dynamic rupture pressure of a flash tube lacquer seal as experienced by the 

flash tube. The flash tube was filled with 350-mg Class VI black powder (3, 4) and held in the 

fixture. An electric match provided the ignition stimulus and was placed behind the black 

powder in a void volume that was approximately the same as that of the conventional primer. 

The pressure was monitored with a Kistler 211B1 pressure transducer behind the electric match. 

The pressure-time history was recorded on a Nicolet Integra 20 digital oscilloscope. The rupture 

event was also monitored with a Phantom IV high-speed camera. 

A second fixture simulated the inside of an M788, M789, or M799 round. This simulator was 

filled with inert propellant. The flash tube was held in a truncated casing (an actual casing was 

truncated to form a stub base with the proper interior geometry of the round) of an M789 round. 

The black powder in the flash tube was ignited by an electric match, and the pressure was 

monitored. Pressure in the propellant bed region was measured near the projectile location and 

near the breech. Figure 4 shows a simplified schematic of this fixture. 

3. Results and Discussion 

A previous study (2) determined the strain-related physical properties of the nitrocellulose (NC) 

lacquer seal. However, these results only described the physical behavior of the lacquer seal 

itself. Effects such as the solid black powder pushing up against the seal or possible weakening 
3

Figure 3. Simplified schematic of open air fixture to obtain the dynamic rupture 

pressure of a flash tube seal. 

Figure 4. Simplified schematic of fixture to simulate the early-phase burning in 30-mm ammunition. 
4

of the seal due to the temperature of the flame, etc., were carefully removed. In the current 

study, all the effects of a flash tube in typical operation were examined because the flash tube 

itself was filled with the correct loading of the proper grade of black powder. 

Figure 5 shows the pressure-time history produced by the ignition of 350 mg of Class VI black 

powder in a properly functioning flash tube that vents into open air (see also figure 3). The 

pressure-time history of a standard NC seal (1) indicated that maximum pressure was reached at 

~2 ms from black powder ignition. Rupture and essentially complete venting occurred by 4 ms. 

The maximum pressure reached was nearly 41 MPa. 

0

5

10

15

20

25

30

35

40

45

50

0246

Time (ms)

Pressure (MPa)

Nitrocellulose (av. of 2)

Beckopox (av. of 2)

Star brite

Viaktin

Figure 5. Pressure-time histories of interior of flash tube using selected seal materials. 

Other coating materials were tried as possible NC replacements. It was hoped that candidates 

that were more environmentally friendly (also known as “green”) would be found. The 

candidate materials were selected so as to have reduced (or totally eliminated) volatile organic 

compounds (VOC) in their composition or use (5). They were also selected so as to not contain 

any U.S. Environmental Protection Agency (EPA) Title I, Section 112 hazardous air pollutants 

(HAP) (6). With these restrictions in mind, the search was narrowed to materials that were 

aqueous, ultraviolet (UV)-activated, or thermal cured. Of the materials tested, those in figure 5 

showed interest for demonstrating important aspects of expressed physical properties in the 

selection of a seal material for a properly functioning flash tube. 

Pressure-time histories of the rupture of a seal fabricated from three of these materials are 

depicted in figure 5. Beckopox (Solutia, St. Louis, MO), a heat-cure material, most closely 

matched the NC lacquer. Other materials such as Viaktin (Solutia, St. Louis, MO) and Star brite 

(Star brite, Ft. Lauderdale, FL) showed dramatically different behavior in this application. The 

NC (av. of 2) 
5

rupture pressures from these last two materials were much lower than that of the NC seal. The 

rupture pressure of the Star brite seal was especially low. This degraded behavior was deemed 

sufficient to simulate damaged NC seals. A damaged seal (cracked or missing, for example) 

would likely produce a lower maximum pressure and possibly lose a portion of the black powder 

into the propellant bed before ignition. 

The results from the Viaktin and Star brite suggest that not all of the black powder was 

consumed. Indeed, the high-speed video showed burning particles ejecting from the Beckopox 

and NC seals only (see figure 6). After each test, the table on which the fixture was attached was 

swept for unburnt particles. Such particles were found only for the tests with Viaktin and Star 

brite seals (see figures 7 and 8). Some of the particles that were recovered were essentially the 

same size as the original black powder. Other particles were reduced in size as if crushing or 

other hydrodynamic particle reduction processes had occurred. It may be that during the earlystage ignition of the flash tube that some portion of the black powder was forced out of the flash 

tube prior to its ignition. Such particles of black powder would not contribute to rapid ignition of 

the propellant bed. 

Beckopox 

NC 

Opening of a Viaktin 

Flash Tube 

Figure 6. Frames from high-speed video after seal rupture into open air. 
6

Figure 7. Photograph of original black powder particles. 

Figure 8. Photograph of recovered black powder particles 

from test with Viaktin. 

The simulator fixture in figure 4 was used to identify some of the conditions that would exist in 

the propellant bed during and after the functioning of the flash tube. The propellant bed in the 

following tests was filled with an inert propellant grain used earlier in 25-mm simulator tests (7). 

The first test was with a standard NC seal. Figure 9 shows the pressure-time history. The 

maximum pressure in the flash tube was ~42 MPa prior to rupture at near 1.7 ms. The breech 

pressure began to rise steeply at 2.2 ms to ~2 MPa by 2.8 ms, and the forward pressure rose more 

slowly to the same pressure by ~4 ms. The pressure then decreased, as is typical with heat loss 

from the gases to the inert grains after the propellant (black powder in this case) has burned out. 

The soot from the black powder penetrated into the inert propellant bed at ~60% of the bed 

length. The maximum bed pressure is similar to pressures observed in some Air Force tests with 

GAU-8 extract propellant (used in GAU-8/A ammunition at the time) and a WECOM flash tube 

(similar in construction and in black powder loading to the flash tube used in this study) at 

comparable temperature (8).
7

0

5

10

15

20

25

30

35

40

45

0 2 4 6 8 10 12 14 16

Time (ms)

Pressure (MPa)

Flash Tube Pressure

Breech Pressure (x5)

Forward Pressure (x5)

Figure 9. Pressure-time history of rupture of a good NC seal in the 30-mm simulator. 

The test simulation of a damaged seal used a flash tube with a Star brite seal. The ignition of the 

flash tube produced the pressure-time history in figure 10. The pressure in the flash tube reached 

a maximum pressure of 2.5 MPa in 1.5 ms, but did not begin to fully vent until ~3 ms. At this 

point the pressure in the propellant bed began rising and continued rising for ~4 ms until it 

reached a maximum pressure of ~0.02 MPa that held steady for at least 15 ms. Such pressure 

behavior could indicate that black powder particles left the flash tube without burning and 

entered the propellant bed prior to combusting. After the particles were dispersed to some extent 

in the bed they burned more slowly and released gases at a sustained level during the time 

window observed. The soot from the black powder penetrated ~47% of the propellant bed. 

There is no way to tell how much of the soot was deposited during the initial release when the 

seal ruptured or from the prolonged burning of sprayed black powder particles after the flash 

tube vented. 

Comparison of the pressure-time histories (see figures 9 and 10—please note the difference in 

scale and in the multiplicative coefficients in the legends) of a properly functioning flash tube 

seal and a damaged flash tube seal shows dramatic differences. The damaged seal produced 

more than an order of magnitude reduction in pressure in the flash tube and nearly a two-orders 

of magnitude reduction in pressure in the propellant bed. A side-by-side comparison of the two 

data sets using the same vertical scale shows more dramatically these differences (figure 11). 

These reductions in pressure and burning particles (see also figure 6) should produce degraded 

performance in the functioning of ammunition with a damaged seal. 
8

0

0.5

1

1.5

2

2.5

3

0 2 4 6 8 10 12 14 16

Time (ms)

Pressure (MPa)

Flash Tube Pressure

Breech Pressure

(x50)

Forward Pressure

(x50)

Figure 10. Pressure-time history of rupture of simulated damaged seal in the 30-mm 

simulator. 

Figure 11. Side-by-side comparison of a good and a simulated damaged seal in the 30-mm simulator. 

With the study of several candidates simultaneously, it was obvious that the physical properties 

of a replacement material for a particular grade of NC lacquer should be considered before the 

final selection. Even changing to a different NC lacquer in an effort to affect the strength, 

brittleness, thickness, etc., the new seal should be tested for physical properties so that the goal 

of improving the flash tube operation is achieved instead of actually degrading the performance. 
9

4. Summary 

The lacquer seal on a flash tube for 30-mm ammunition was shown to perform more functions 

than a simple environmental seal. Use of fixtures that vented the output from the flash tube into 

open air or into an inert propellant bed demonstrated that proper functioning of the seal could 

greatly affect the conditions present during the early-phase combustion of the propellant bed. 

With damaged or defective seals, both pressure in the propellant bed and burning particles 

vented from the flash tube decreased dramatically with the ability of the seal to hold pressure as 

the black powder was ignited. 

If changes are to be made to the standard NC seal material, physical properties that affect the 

actual function of the flash tube and the operating of the ammunition should be measured and 

evaluated. Other physical properties such as performance at hot and cold temperatures (not 

undertaken in this study) should also be obtained and compared to the standard NC seal. This 

study showed that such properties, even though possibly not visible to the naked eye in an 

unused seal, could dramatically affect the operation of the flash tube and possibly degrade the 

performance of the affected ammunition.
10

5. References 

1. MIL-L-296B. Purple Lacquer, 2000. 

2. Howard, S. L. Flash Tube Lacquer Seal Dynamic Rupture Strength in 30-mm Ammunition. 

Propellants, Explosives, Pyrotechnics 2003, 28 (5), 256–258. 

3. U.S. Army Armament, Research and Development Center. Flash Tube Assembly. Part No. 

11825903, Dover, NJ, January 1982. 

4. U.S. Army Armament, Research, and Development Center. Flash Tube Assembly. Part No. 

11075870, Dover, NJ, December 1976. 

5. U.S. Environmental Protection Agency website. http://www.epa.gov/ebtpages/ 

pollchemicvolatileorganiccompounds.html (accessed 2003). 

6. U.S. Environmental Protection Agency website. http://www.epa.gov/ttn/oarpg/t3fs.html 

(accessed 2003). 

7. Chang, L. M. Interior Ballistic Simulations of 25-mm Gun Charges; BRL-TR-3330; 

U.S. Army Ballistic Research Laboratory: Aberdeen Proving Ground, MD, 1992. 

8. Fong, C.; Shiver, T. W. Ignition Pressure. Waves and Propellant Grain Fracture in the 

GAU-8/A 30mm Gun; AFATL-TR-82-84, Air Force Armament Laboratory: Eglin Air Force 

Base, FL, 1982. 
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