Redesign of BBU-35

BBU-35 Product Improvement Statement of Objectives Purpose and Background: The AF is currently experiencing several performance issues in using the BBU-35 Impulse Cartridge (IC). The purpose of this Statement of Objectives (SOO) is to develop a Product Improvement Plan (PIP) to address and correct these issues in a new design. The first issue is a failure to poll when loaded with chaff or flares in a dispenser. The aircraft sends a small current to the IC to detect whether it is present and servicable or not. Failure to poll results in false counts and decreased opportunities to eject countermeasures. Another problem is corrosion both on the exterior of the cart and at the bridge wire. Either type of corrosion can render the IC unusable. A third element to be corrected is excessive and inconsistent output. Excessive output results in higher set back forces as well as high exit velocities for the countermeasures. High velocity flares can leave the field of view of the threat too quickly, thus reducing their effectiveness. The final potential improvement is that the current IC has low success in igniting certain flares, specifically boron based flares like the M212. Objectives: The end objective is to develop a redesigned BBU-35 that is a form, fit, and function replacement for the current IC. The new design needs to have the same physical dimensions, same performance characteristics, and same all fire and no fire limits. Latitude for the new design includes propellant types and amounts, case materials, sealing method and/or closure type, and internal dimensions. The BBU-35 is used on several different types of inert chaff, pyrotechnic flares, and pyrophoric IR decoys. Developing an improved IC will require evaluating the requirements of each application. See table 1 in appendix A for items and pertinent characteristics. In addition to force, pressure, and velocity characteristics, the ability to ignite pyrotechnic flares is critical. The improved impulse cartridge must be able to pass the first article test and lot acceptance test as described in SP7729436. If any new propellant or explosive types are used, the cart will also have to pass safety of flight testing and hazard class testing. DATA: To qualify a new BBU-35 design, the AF will require test reports for performance testing, functional testing, safety of flight testing and hazard class testing. The AF also requires that the TDP for the improved IC be transferred to AF ownership at the conclusion of the PIP effort. Interested parties shall provide a rough estimate of expected costs of this redesign project.