Owing to the hea lth threat of perchlorate contamination of groundwater, we have re-formulated pyrotechnic compositions used in spectrally balanced decoy flares, as well as in red, green, and yellow signal flares so as to remove the perchlorate ingredient while still maintaining performance characteristics that meet or exceed those of the in-service devices. The perchlorate-free decoy flare composition chosen for scale-up was successful in match ing the spectral ratio and infrared emission intensity of the older of two types of spectrally balanced flares. Chern ical equilibrium computations have shown that it should also be possible to formulate a successful organic-fueled, perchlorate-free substitute for the newer of the two types of flares. We have also conducted extensive laboratory and prototype scale testing of perchlorate-free red flare compositions. Prototype scale test<; revealed a degradative aging problem with the hygroscOj)ic calcium nitrate ingredient. We then selected a slightly modified red composition that we are performance and ignition sensitivity testing, prior to proceeding with fonnulation qualification, final type qualjfication

Novel yellow-light emitting pyrotechnic compositions absent perchlorate oxidizers were investigated for use in the Mk 144 marine smoke and illumination signal. In laboratory-scale testing, three candidate formulations met or surpassed performance metrics of luminous intensity, dominant wavelength, color purity, and burn time when compared to a mock Mk 144 formulation which currently utilizes the environmentally hazardous potassium perchlorate. Also, one identified formulation does not utilize any barium compounds which may be the focus of future regulations. Furthermore, these candidate systems exhibited similar insensitivity to electrostatic, friction, and impact ignition stimuli in comparison to the mock Mk 144 formulation. Therefore, replacement formulations for the Mk 144 marine smoke and illumination signal have been identified with increased performance, environmental sustainability, and acceptable safety characteristics.