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|
PowerLabs NEW Rail Gun!
PowerLabs Rail Gun 2.0 Research!
 
RailGuns are expensive! This project was made possible by the
generous contributions of my sponsors. Would you like to sponsor PowerLabs
research? Please donate *any* amount. Every little bit helps and you can
be sure your money will be put to good use :-)
Project Introduction:
 From
its conception, the original PowerLabs Linear Magnetic Accelerator ("Rail Gun",
or "Railgun") was conceived for the primary goal of simply
proving that it could be done; on a low budget, with common materials and
powered by a never tried before electrolytic capacitor bank.
In that, it was extremely successful: Not only did the gun fire
flawlessly over 30 times (it is not uncommon for research rail guns to break
down in the first shot), but it also attracted vastly more attention than
I could ever have hoped for:
After its page generated hundreds of thousands of hits, the gun was featured on
Discovery Channel, TV6, numerous newspaper
and magazine
articles, and earned me several job offers from the private sector, research
institutes, and industry. The highlight of the popularity of this project
came in the form of two separate offers from laboratories associated with the
department of defense (DoD), which, apparently can't hire me because I was
not born in the USA (someone must have forgotten that the majority of the best
scientists and engineers in the world weren't born here)...
The original railgun design was completely
experimental; built, assembled and operated solely by
myself, on my first year of engineering school and being entirely based on
my knowledge of electricity and magnetism at the time. With the catastrophic failure of the injector casing and the
injector/rail assembly during a full power shot, I found the extra
motivation I needed to re-design the gun so that my research in this area
could continue. Of course, by now, with 3 years of engineering school and
extensive research on the subject, I expected even greater successes.
Project Description and Goals:
The objective of this project is to successfully design and
construct a linear electromagnetic accelerator capable of accelerating a
lightweight
payload to velocities greater than 1000m/s so that high velocity
erosion in the rail/armature interface can be studied and a means for
minimizing this erosion be investigated.
Rail Guns are not by any means a new technology; 50 years ago
when the first true rail guns were built and fired it was believed that they would
provide a means to accelerate objects to virtually any desired speed, replace conventional weapons
and provide cheap
orbital launches for small payloads. Today, despite enormous advances in
the technology, the maximum muzzle velocities attainable are nowhere near
what was once believed possible, and railguns remain confined to the laboratory where some
times the rails need to be removed and resurfaced after every shot. The
cost of obtaining high acceleration through electrical action between
sliding contacts is the rapid destruction of those contacts through arcing
and friction. I am not alone in believing that we are very close to a
solution to this erosion problem, and it is my belief that once this solution is found it will
have profound implications our understanding of materials science, power
transmission, high velocity friction, and open new doors to the fields of
transportation, defense, manufacturing, and more.
As I embark on this
research once again to further my knowledge in various fields of science I hope
to make a significant contribution to the field of electromagnetic
acceleration, which has fascinated me ever since I first learned about it,
and hopefully secure a job offer in this field.
Theory
(a simplified overview):
 RailGuns differ from other means of accelerating objects in that the
acceleration in the rails occurs purely by magnetic repulsion. This magnetic
force is termed a "Lorentz Force", and it has been shown to be:
Frg = 1/2*dL/dX * I2 [1]. The dL/dX term can
also be written as L', the inductance gradient of the rails. From
this equation it can thus be seen
that even in a well designed Rail Gun (high inductance gradient),
the most predominant factor in determining exit velocity will always be the power supply
current.
Thus it follows that in order to produce high muzzle velocities, long rails and/or very high
currents must be used. Unfortunately, maintaining a high current through a
long pair of rails requires a lot of energy (Current * Voltage *
Time), and with high currents high rates of rail erosion have so far been
unavoidable.
The exit velocity of a rail gun can be estimated through the equation:
V=u+L'/2m * (integral 0→t) I2dt
[1] , where u is
the injection velocity.
Although this equation is of limited use unless the
exact shape of the current pulse is known, it once again it
demonstrates the importance of a high current. It also states the obvious
fact that higher exit velocities will be attainable with higher injection
velocities. Not easily seen from the equation, but equally important, is the
fact that at higher injection velocities the electrical arcing and ohmic
heating between the projectile
and the rails will not have as much time to heat the rail surfaces to
vaporization. Thus, up to a certain point, a higher injection velocity will
help minimize rail damage[10]. It will also prevent rail/projectile spot
welding, which can occur at zero injection velocities and low powers on
metal/metal contacts. Given the energy
expenditure of accelerating the projectile electrically, and the advantages
of pre-injection, it makes sense to impart as much initial velocity to the
projectile as possible, and only then allow the electric action to do what
it is most effective at: attaining velocities that would not be feasible
with a gas injection mechanism alone.
Resistive losses in a Rail Gun are given by:
Wr= R0(integral 0→t)i2dt = 2R0(mv)/L'
. With mv being the momentum of the projectile, it can be seen
that energy loss in a railgun is proportional to projectile momentum (not
kinetic energy, as might be expected), and can be minimized by increasing
the induction gradient. This would imply that rail guns are most efficient
at accelerating light payloads, which would steer research towards smaller
bores; however it has been shown experimentally [9] that with very small
calibers (<18mm) the efficiency of a railgun decreases with smaller
size bores. Clearly other factors are involved, some of which still
unknown.
For the sake of simplicity and clarity I will limit myself to these and
only a few more equations on this write up. The interested reader is
invited to seek further knowledge by reading the sources cited at the
bottom of the page (as opposed to creating yet another copy of my design,
like so many others seemingly incapable of creative thought and
engineering design)
Power Supply and pulse shaping:
The Lorenz force decreases drastically with a reduction in current, and
below a minimum current the accelerating force drops below the projectile
frictional force and thus power is dissipated with no extra kinetic energy
being imparted into the projectile. In order to counter this loss, the
ideal railgun electrical pulse shape is a square wave with rapidly
increasing pulse current, a high plateau, and a fast current decay. Such a pulse shape
can be approximated through a Pulse Forming
Network (PFN).
As with the previous Rail Gun, this power supply consists of Cornell-Dubilier Inverter Grade
capacitors,
each rated at 6300uF and 400V (450V Surge). Operating Temperature is
-40C to +95C. These capacitors utilize the latest technology in
electrolytic capacitor construction to store 640J each in a can measuring
only 3" dia. x 5.63" length and weighting 900grams each.
Each individual capacitor has a 50KOhm 10W wire wound resistor for charge
equalization and also to serve as a bleeder to prevent unwanted charge
buildup when power is switched off. They are charged through a 900Ohm
current limiting resistor and can be safely discharged through a 6.25kOhm
resistor bank mounted inside the bank.
In order to counter skin
effect related losses the capacitors are inter connected by very large
surface area (30in^2) oxygen free copper strips each 0.064" thick
(1.6mm). The bank is internally fitted with a
Fluke 80K6 6-kV probe for voltage monitoring.
The capacitors in the power supply for this railgun has been generously donated by
S. Parler of Cornell-Dubilier
Electronics.
Rails and Rail Enclosure Design:
 The
magnetic field produced by the rails can be estimated by the Biot-Savart
Law, which calculates the field of a current carrying long straight wire;
B = u0I/2pir. The plot on the right shows how the
magnetic field around a wire rises linearly with current. The wire in this
case has a radius of 0.00635m and its length is dimensionless. Notice how
one Tesla is not achieved until 35000amperes flow through the
wire: Producing a strong field in a straight wire requires vast amounts of
current, and there are several more efficient ways to achieve these high
field strength values without resorting to several tens of thousands of
amperes. Some of these methods are to be explored in another, future
Railgun design.
 The plot on the
left illustrates how the magnetic field strength drops with distance
between the rails and increases with decreasing rail width. Both
relationships are exponential. Seeing as the acceleration is a product of
the force created by the magnetic field strength acting on the mass of the
armature, it can be seen that ideally, for the highest possible field
strength a rail gun would have very thin rails, very close together (not
surprisingly, this translates into a large L' value), running a very high
current. Unfortunately these two parameters limit the mass that can be
launched, and also exacerbate the rail erosion problem, as thinner rails
have less surface to dissipate the heat produced during firing.
Ultimately, as is the case with virtually every other engineering design,
a practical Rail Gun design represents a compromise of several factors
where rail life, muzzle velocity and payload mass are carefully balanced
to meet the requirements of what is expected from the gun.
In my previous Railgun design I utilized two
flat parallel rails facing with their broad sides; this provided the
greatest amount of surface area for the rail/projectile contact interface
so as to minimize arcing and arc damage while at the same time maintaining
the rails very close to one another, thus maximizing the magnetic field
strength. Other research rail designs include flat rails with narrow sides
facing, square rails, round bores, multiple symmetrical rails, and others.
According to [5] the ideal rail geometry is plate like, with a
Width/Height ratio of >2. This provides a high L' value, although as
indicated by the Lorenz force calculation, a high inductance gradient is
not required nor does it guarantee a successful design.
For this design I will attempt a square bore. There is good evidence to
its superiority to a round bore design[], and, contrasting with the
previous rectangular bore design I employed, the larger rail spacing will
allow for a greater variety of projectiles to be tried (at the cost of
less magnetic force, however).
The repulsive force between the two rails of an electromagnetic
accelerator can be approximated by [7]
K=-µ(I2/16π)*(L/D)
µ= Magnetic Permeability in Vs/Am (4π*10-7)H
m-1[8]
I= Current through rails in Amperes
L= Length of rails in meters
D= Distance between rails in meters
 Taking
into account a rail length of 60cm, rail separation of 1cm and a peak
current of 100kA the maximum repulsive force between the rails becomes
15KN. This amounts to 3372lbs. The mean pressure on the rails is thus
238PSI. Rail repulsive force becomes 10500lbs with the addition of a
500PSI injector. This load is assumed to be shared equally by the 28 bolts
holding the structure together, thus requiring the bolts to clamp a 374
pound force each. By pre-tensioning the bolts to a pre determined torque
it is possible to preload the entire structure to a force greater than the
total repulsive force of the rails during firing, and in this way ensure
that no rail deflection occurs, maintaining barrel integrity, seals, and
ensuring continuous contact between the armature and the rails.
This does not, however, apply to plasma armatures; as experience from the
original RailGun demonstrated, the actual pressure inside the bore during
a plasma armature firing will be vastly more than this (enough some times
to shatter the enclosure). Peak pressures of over 55000PSI can be obtained
with plasma armatures The final design
addressed the weak spot where the injector met the gun itself by
eliminating it, making the entire gun a single 24 inch long barrel divided
equally between the 12" rails and a 12" channel through which pneumatic
acceleration takes place. The rails themselves were milled from a large
piece of copper, thus eliminating the need for any welding or brazing.
On these pictures the "ears" created by milling the rails in an "L" shape
can be seen. Also seen below, behind the bottom rail, is the garolite G-11
"fake rail" where the projectile rides during the initial pneumatic
acceleration stage.
Below the spot where power is fed into the gun
can be seen more clearly. This had to be milled very accurately since that
is the point of highest plasma pressure in this particular design.
Material choices on this gun were as follows:
The enclosure is constructed of 1/2" thick
Garolite G9, one of the strongest composites currently available. G9 is
both extremely strong, very stiff, non conductive and non magnetic.
The rail spacers are a 1/8" thick strip of
Garolite G11 laid over the G9 enclosure. G11 has similar properties to
G9, however during tests [] it showed the lowest electrical ablation
rate of any non ceramic tested. The low ablation rate means the gun
should be able to fire several shots before these need to be replaced.
Rails are oxygen free copper, 3/4" wide,
1/8" thick, 1ft long.
Bolts, nuts and washers are 18-8 Stainless
Steel, the highest grade SS available. Stainless was chosen because it
is non magnetic; a magnetizeable material around the rail will carry
with it magnetization losses. Ideally a small performance gain could be
obtained by having non conductive bolts, but there are no such bolts
available today which would be strong enough for this application.
Injector:
I would like to publicly thank
Calumet Machine for
assisting in the manufacture of the injector gas system; their expertise
was critical in choosing and locating the components necessary for the
safe realization of this high pressure system. It was a pleasure working
with you guys and I am still amazed that you managed to make a paintball
tank-steel hydraulic coupler-brass pipe fitting adaptor!
 
If full power was to be applied to a
static armature the rails and whatever was between them would
instantaneously melt under the intense localized heat produced by Ohmic
heating as 100thousand amperes tried to make it through the contact
resistance. In order to prevent the Rail Gun from
becoming a spot welder it is necessary that the armature be moving
with some initial speed prior to electromagnetic acceleration.
Furthermore, there is no point in wasting valuable electrical energy
stored in expensive capacitor banks to accelerate the projectile during
the first couple hundred meters per second; compressed gas is a far more
efficient and economical way of pre-accelerating the projectile until it
starts moving at speeds where electrical acceleration makes more sense.
Finally, with increasing injection velocities, there is a corresponding
decrease in rail erosion, as the projectile spends less time at any given
spot on the rails and thus produces less heating and associated material
loss.
 
With this in mind a new injector was designed to provide the highest
injection velocity possible. The primary design constraint was the
solenoid valve; the highest pressure attainable for a reasonably priced
rapid dump high flow solenoid valve was 1200PSI working pressure. As such,
the entire injector has been designed around this component. The 1200PSI
will place a force just shy of 200pounds on the projectile, accelerating
it at at over 20thousand "Gs". Consequently, it will also place a large
amount of force on the gun breech, which is why 1/2 thick Aluminum 6061
was chosen as the support material. The mating surfaces were polished to a
mirror shine and silicone gasket maker was used throughout in order to ensure everything is gas tight. Ideally this
injector should be able to achieve Mach 1 compared to the old design which
was only able to push 150m/s at 500PSI.
Armature Design:
 Perhaps the single most important factor determining Rail Gun
efficiency is the degree of contact between the rails and the armature.
Ideally a perfect electrical contact would exist between the two and cause
resistive losses to be virtually negligible when compared to the rest of
the circuit. These low resistive losses would make for a very low voltage
drop across the rails, which would cause very little resistive heating,
zero arcing and almost no rail erosion. Unfortunately, maintaining perfect
electrical contact between two metallic surfaces that are very small and
move at extremely high speeds relative to one another has so far eluded most Rail
Gun designers. Solid Armature Rail Guns start off as such and quickly
become transitional or hybrid as the metallic contact breaks down and
arcing begins at 1.5km/s+[2] forming a plasma interface. Above 4000m/s rail guns are almost
exclusively of the plasma type [3], but secondary arcing tends to limit
their performance by lowering efficiency as longer barrels are made [4]. Currently there are 3 approaches to
armature design: Solid armatures employing a V-notched or U-shaped tail,
which is forced against the rails under the high currents present in
firing (most common), brush armatures which utilize hundreds of small
metallic wires to maintain some degree of contact with the rails despite
small irregularities (such as with the French PEGASUS design[]), and plasma
armatures, which allow arcing to occur in a controlled fashion behind the
projectile and utilize that arc to propel a non conductive projectile down
the barrel, despite heavy rail erosion and resistive losses. These were at
some point in time believed to be the only means of obtaining velocities
above 5km/s, although advances in rail and armature design have made it
possible for solid armature designs to perform at similar levels.
In the new PowerLabs design a completely novel armature will be employed
which has never before been fired from a rail gun; through advances in
materials science a special copper / carbon composite has been made which will retain its
dimensional stability due to the extreme heat resistance of carbon, while
at the same time not causing excessive resistive losses thanks to a high
degree of copper imbedded in it. Other advantages of this material include
low residue, the inherent lubricating properties of carbon, ease of
machining (can be machined with HSS tools), and the fact that it can never
weld itself to the rails. On this photo the compound can be seen being
heated with an oxygen acetylene cutting torch. The 5000F flame leaves the
carbon virtually unharmed even after several minutes, and copper can be
seen evolving from inside the compound, coloring the flame. Much like
composite materials have made it possible to construct strong lightweight rail
enclosures, different composites should also make it possible to construct
a lightweight armature that will withstand the stresses of electromagnetic
firing and accelerate payloads with superior performance. Other
composites will be tried, as well as conventional armature materials such
as aluminum and plasma.
The machined rounds weight 4.27grams
A more conventional armature was also produced from pure, electrical grade
aluminum (Al1100). Aluminum has conventionally been the preferred armature
material for both research and military railguns. There are various
reasons for this:
Aluminum has one of the lowest resistances per
unit weight of any material,
It has a lower melting point than the rails,
reducing rail erosion somewhat,
It has a low density, so when used as a sabot not
a lot of energy is wasted accelerating it,
It is easily available and easy to machine.
Al1100 was also the material of choice for my
original railgun. I found, as others did, that when using any solid
armature the rail/armature interface must be perfect; should the sliding
armature lose contact with the rails for just an instant, it will
automatically start an arc which then consumes very large amounts of power
and metal. Plasma armatures propelling
composite projectiles were planned, but not attempted at this time.
Charger:
For the rapid, safe, controlled charging of the capacitor bank and the
safe firing of the gun the following charger was devised:
Current limited, 2kW, 0 - 4kV variable voltage, 1A output current.
The charger feeds two microwave oven transformers in series through a
Variac, and then charges the capacitor bank through an ammeter, to
monitor current. The voltmeter in the charging supply monitors a
Fluke® High Voltage probe within the capacitor bank itself. For safety
power is controlled by a key, and the main switch routes power through
a relay so that the gun can not be fired whilst charging. This is
particularly important due to the massive back EMF that occurs when
the gun fires; this has literally exploded diodes in the past.
Firing is performed by routing power to a 110V outlet within the charger
which energizes the solenoid on the gas injector. The fire switch is,
of course, a big red button...
Completed Device:
 Here
are some shots of the gun right before it was fired for the first time.
You will notice a very large inductor next to the barrel; this was
necessary to slow the electrical pulse down to a level where the current
no longer cratered the rails at the point of initial contact.
Feed lines are: Argon Gas (Top right hose into gas injector)
Power (two white cables on the right)
Fluke Voltage Divider for charge level monitoring (left)
Injector solenoid power (cable from top)
  
Results!
.jpg)
Railgun 2.0 was originally fired on the summer of 2006 for a film
crew filming an episode of a Discovery Channel show. For those tests, the
Carbon/Copper sintered powder composite was utilized.
This armature, much to my dismay, EXPLODED inside the barrel, creating an
incredible blast and a shower of fragments from the muzzle.
Since the gun was designed to withstand over ten thousand PSI, no damage
of any sort occurred and filming went on as planned. The exploding
armatures looked spectacular on camera, but didn't do much more electrical
efficiency. After several shots were fired carbon vapor deposited itself
on the insulators and created a rail-to-rail flashover condition.
A further analysis revealed redeposited copper vapor all over the
rail channel. It appears as though the carbon/copper composite was too
resistive for the particular currents encountered in this gun and
localized heating lead the copper within it to vaporize, causing it to
fracture from within. It may still prove to be an excellent projectile for
rail guns, but only so long as a low current density and limited energy
level are adhered to.
 The second
round of tests occurred in September 2007, again for Television. This time aluminum armatures
were utilized and these, despite being deformed by the intense magnetic
forces within the gun, held together and accelerated inside the gun to a
high speed.
Again the chronograph did not work so velocity readings were
unavailable. It is not known if the problem relates to muzzle flash,
plasma, or EMP. More research is needed in this area.
After several shots the gun's efficiency decreased markedly. It was
found that the insulator covering the first inch of rails had been blown
off and now the armatures were making contact with the first inch of
rails, before the power feed. This meant that the Lorenz force was
actually slowing the projectile down. Tests were then stopped.
More to come!
Parts List and Construction
Pictures:
Line
Part Number
Description
Quantity
1
8710K147
Grade G-11 Garolite Sheet 1/2" Thick, 12" X 24"
1 Each
2
8964K74
Alloy 110 Copper Rectangle 1/8" Thick, 3/4" Width, 6' Length
1 Each
3
8661K142
Grade G-9 Garolite Sheet 1/8" Thick, 12" X 24", Brown
1 Each
4
92198A113
18-8 Ss Hex Head Cap Screw 1/4"-28 Thread, 2" Length
1 Pack
5
90101A235
18-8 Ss Hex Thin Nylon-Insert Locknut 1/4"-28 Screw Size, 7/16"
Width, 13/64" Height
1 Pack
6
90945A760
18-8 Stainless Steel Nas 620 Flat Washer 1/4"L Sz,no.
C416L,.255"ID,.468"OD, .029" Min Thk
1 Pack
7
7583A12
Permatex Silicone Hi-Temp Form-A-Gasket Red 3 Oz Tube
1 Each
8
75065A69
3M Scotch-Weld 2-PART Epoxy Adhesive 1838 Green, 2-OZ Tube
1 Each
9
8636K21
Glass-Filled Ptfe Sheet 1/32" Thick, 12" X 12"
1 Each
10
7607A11
Teflon Bonding Kit
1 Each
11
8975K436
Alloy 6061 Aluminum Rectangular Bar 1/2" Thick, 5" Width, 1' Length
1 Each
12
1749K12
Polycarbonate Rectangular Bar .220" Thick, 1" Wide, 4' Length, Clear
1 Each
13
2474T311
Alloy 1100 Rectangular Bar 3/8" Thick, 1" Width, 1' Length
1 Each
Works Cited:
Prior to the design of this gun the author studied approximately 900
pages worth of conference proceedings, journals, pHD and Master's Thesis and
technical papers on the subject. Below, for those wishing to pursue further
research in this area, are some of the ones that proved most useful and are
quoted in this page.
[1]S.B. Pratap, J.R. Kiltzmiller, T.A. Aanstoos, "Optimization and design of
the air core compulsator for the Cannon Caliber Electromagnetic Launcher
System (CCEML)", Proceedings of the Ninth IEEE Pulsed Power Conference, pp.
29-35 1993.
[2]J.V. Parker, "Electric Guns", Paper from the Pulsed Power Course held in
Austin Texas, November 1995.
[3]Beach, Fred C. "Design and Construction of a One Meter Electromagnetic
Railgun". Naval Postgraduate School Monterey CA.
[4] Akira Yamori, Yukari Ono, Haruya Kubo, Migiwa Kono and Nobuki Kawashima.
"Development of an Induction Type Railgun", IEEE Transactions on magnetics,
Vol. 37, No.1 January 2001
[5] Aleksey E. Poltanov, Anatoly K. Kondratenko, Alexander P. Gilinov, and
Valery N. Ryndin. "Multi-Turn Railguns: Concept Analysis and Experimental
Results". IEEE Transactions on Magnetics, Vol. 37, No.1, January 2001
[6]Hartke, John P. "Characterization and Magnetic Augmentation of a Low
Voltage Electromagnetic Railgun". Naval Postgraduate School Monterey CA Dept
of Physics.
[7]E. Igenbergs, "A symmetrical Rail Accelerator". IEEE Transactions on Magnetics, Vol.
27, No.1, January 1991.
[8]CRC Handbook of Chemistry and Physics, 80th Edition
[9] Akira Yamori and Nobuki Kawashima,
"Characteristics of a High Efficiency 300kJ Railgun", IEEE Transactions on
Magnetics,
Vol. 31, No.1 January 1995
[10]R.A. Marshall, Moving contacts in macro-particle accelerators, Aus-US
seminar on energy storage, compression and switching, Nov. 1977
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People have visited this page since 21/02/02.
Last updated
02/11/07
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© 2002 -2007 by Sam Barros. All rights reserved.
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