Feature

Recent developments in Exploding Foil

Initiator (EFI) based electronic safety,
arming and initiation systems
by Simon Bower mSc ceng miet and Dr Brian M Coaker phd ceng cphys cSci miet minstp whSch

In modern explosive systems, low-voltage Exploding Foil Initiator (EFI) detonators

electrically-driven ‘hot wire’ detonator exploding Foil initiators (eFis) have been enable optimum switched-energy transfer
systems (incorporating primary explosive) used since the early 1980s3 as a safe and from the firing capacitor into the eFi bridge;
have increasingly given way to higher- reliable method of initiating insensitive this low-loss configuration supports both
voltage explosive detonators (such as explosive material in the first stage of an (i) surface-mount detonator designs
Exploding Bridgewire (EBW) and Exploding explosive chain.4, 5 established e2v designs mounted directly onto the eSau
Foil Initiator (EFI) types) containing comprise a copper-kapton laminate / short- (figure 1), along with
secondary explosive.1 The high degree of barrel initiator structure, and are activated (ii) stripline-mounted detonators on
insensitivity2, reliability, precision and by the application of a fast-rising high- interconnect lengths of up to one (1)
functionality afforded by electronic in-line current pulse from a capacitor-discharge metre from the eSau (figure 2).
EFI based systems (coupled with their rapid Fireset circuit (which typically operates in both eFi detonator configurations have
and repeatable activation time) has been the range 2,000v to 3,000v). found application in electronic safety and
applied as a key enabling technology into a
low-inductance strip-line interconnect is arming units (eSaus) in contemporary
growing portfolio of Electronic Safety &
used in the Fireset-detonator assembly to system applications. the use of an
Arming Units (ESAUs) in modern system
insensitive secondary high-explosive pellet
applications.
(hexanitrostilbene - hnS iv) combined with
a high-reliability firing circuit has seen the
use of these eFi detonator formats in single-
Figure 1. Surface-mount eFi detonator.
output, twin, tandem and multi-point
configurations, with a twin eSau initiation
configuration illustrated in figure 3.

Figure 2. Stripline-mount eFi detonator.

Figure 3. twin eSau
configuration using
surface-mounted (left)
and stripline-mounted
(right) eFi detonator
initiation points.

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 Feature

Switching of the low-inductance firing

capacitor can be achieved using a triggered
vacuum switch (tvS), with gas-filled spark
gap and silicon switches also used. the tvS
offers electro-magnetic robustness and
interference immunity benefits in the fireset
within the eSau module, whilst delivering
high-speed, low-loss switching of the firing
capacitor and initiation of the eFi
detonator.6

Low-Energy EFI (LEEFI) detonators

in recent years the desire to reduce the size,
cost and mass of the Fireset has driven the
investigation of lower-energy eFi initiators
which can reliably, safely and precisely
operate at reduced firing voltages. physical
Figure 5. comparative langlie firing trial outcome for standard e2v eFi and e2v leeFi at hot (+85°c) and
embodiment of the 2,000v - 3,000v cold (-54°c) temperatures [solid markers represent firing events, empty markers denote no-fire events].
operating voltage range of conventional eFi
Fireset technology has been constrained by Figure 5 goes on to show the outcome of with an identical explosive pellet
operational requirements and also by the comparative langlie statistical trials to composition and mass (together with
availability of suitably-rated components determine firing performance over the identical output septum geometries) the eFi
(which must survive the extreme temperature range -54°c to +85°c. the test detonator and leeFi detonator designs
requirements associated with munition and uses a software algorithm to derive mean shown in figure 1, in figure 2 and in figure 4
borehole operating environments). and standard deviation parameters from a each deliver an equivalent explosive output.
recent development of low-energy eFi finite sample by pre-determination of Furthermore, careful design of the Fireset
technology has worked to reduce the all-fire required test levels from prior performance circuit and minimisation of firing circuit
threshold of the exploding foil bridge as the test proceeds; the mean and standard losses has enabled equivalent activation
structure, to enable initiators and compact deviation values are then used to calculate times from both eFi and leeFi initiator
Firesets that will reliably operate at firing the aFt and nFt. configurations, recorded in the two series of
levels of c. 1,200v or less7; Stanag 4187 sequential 25ns images of figure 69.
For a standard e2v eFi, the aFt was in the
requirements currently mandate the no-fire
range 1,794v – 1,824v and the nFt 1,398 –
level to be at 500v (or more)8. Figure 4
1,568v, compared to ranges for the leeFi of
illustrates the general arrangement of an
1,189 – 1,227v (aFt) and 702 – 1,010v (nFt)
e2v low-energy eFi detonator (leeFi): this
respectively: this represents an Figure 6. Fast-frame images of exploding bridge
design has no-fire threshold (nFt) and all- foils at t0, (t0 + 250ns) and (t0 + 500ns), for e2v eFi
improvement in confirmed firing
fire threshold (aFt) characteristics as shown, (left) and leeFi (right) initiators.
performance of >30% (dependent upon
with aFt and nFt values also shown for the
operating temperature) of the leeFi
standard eFi design as a comparison.
detonator over the standard eFi unit.

t0

(t0 + 250ns)
Figure 4. low-energy
eFi (leeFi) detonator,
with aFt and nFt
values for e2v leeFi
and e2v eFi at +85°c
(hot) and -54°c (cold).

eFi (t0 + 500ns leeFi

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define the original position of the pellet.

the test was repeated using a hnS pellet

with a 1mm thick/5mm long stainless-steel
sleeve, as used in the e2v eFi and leeFi
detonator described figures 1, 2 and 4.
Figure 9 shows an image of the progression
of detonation of a sleeved hnS pellet at
25ns frame exposure and 250ns inter-frame
Figure 7. burst currents (i) for eFi (left, 1ka/div) and leeFi (right, 500a/div) initiators at 100ns/div. [the period; again, a pre-image of the pellet has
leeFi trace (right) also shows firing capacitor voltage at 500v/div.]. been superimposed on the detonation
typical burst current-time histories driving detonation wave in sleeved and un-sleeved image to define the original position of the
these events are shown in figure 7 for the eFi hnS pellets was investigated by direct pellet.
and leeFi, showing peak currents of 2,600a imaging of the pellet: the pellet was
these images allowed an estimation of the
(eFi) and 1,250a (leeFi) respectively. initiated using a single standard e2v eFi,
detonation wave velocity to be made,
from a 100nF / 3,000v fire-set. Figure 8
EFI takeover onto explosive material subject to the uncertainty introduced by the
shows the progression of detonation of an
continuing from the initiator output exposure duration, inter-frame period and
un-sleeved hnS pellet at 25ns frame
characteristics shown in figure 6, two further precise initiation time relative to the image
exposure and 250ns inter-frame period: a
series of fast-frame camera images illustrate frames.
pre-image of the pellet has been
the development of the explosive output
superimposed on the detonation image to the clearest data are from the un-sleeved
from the eFi detonator. the velocity of the
pellet images of figure 8 (since there was no
sleeve to block the light which signals the
point of initiation). Figure 8 clearly shows
Figure 8. Fast-frame 25ns some light at the base of the pellet in frame
images at 250ns intervals 1, indicating that the detonation had started
showing initiation of an un-
sleeved hnS pellet (top) using by the end of that frame exposure. in frame
e2v eFi initiator. [original 4 the detonation had progressed beyond
pellet image superimposed the end of the pellet, indicating that at least
on subsequent image frames].

Figure 9. Fast-frame 25ns images at 250ns intervals showing initiation of a sleeved hnS pellet using e2v eFi initiator. [original pellet
image superimposed on subsequent image frames].

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5mm (the length of the pellet) had been

travelled in three exposure durations (3 x
25ns = 75ns) plus three inter-frame periods
(3 x 250ns = 750ns), totalling 825ns. the
velocity calculated in this way is 5mm/825ns
= 6.1 mm/µs, or 6.1km/sec: this is
considered an under-estimate since the
detonation has clearly travelled further than
5mm in the time measured, placing the
velocity in the range 6 to 8 km/sec which
agrees well with other published data (7,000
m/sec) for detonation velocity of hnS10, and
confirming full-order detonation of the
explosive material.
Figure 10. eFi ignitor hardware, demonstrating direct initiation of a deflagrative output.
comparing the detonation images of the
sleeved and un-sleeved explosive pellets, vessel) and achieved peak pressure within a low-inductance triggered vacuum switch
the detonation wave front appears to travel 100ms of triggering the ignitor. this direct- is retained within the miniature fireset, to
with similar velocity in both cases, reaching initiation ignitor configuration can form the optimise the operation of the leeFi
the front face of the pellet (frame 4) and basis of an insensitive munition (im) detonator, and allow the minimum value
being fully-developed at one pellet-length compliant motor safety ignition module14. (and size) of firing capacitor. with a leeFi
from the front face (frame 8) in the same detonator that produces an equivalent
respective image frames (within the 25ns Miniature ESAUs employing LEEFI
explosive output to established e2v eFi-
uncertainty of the frame exposure duration). Firesets
based designs, the miniature eSau provides
with a low-energy leeFi-based Fireset now
EFI takeover onto pyrotechnic material a compact, compliant fuzing solution8 that
operating in the region 1,200v to 1,400v9,
extending the safety and reliability benefits can be readily packaged for single, twin/
the physical size and mass of the Fireset
of insensitivity to rocket motor systems, eFi tandem and multi-point applications.
components can be reduced (especially the
detonator based initiation modules have firing capacitor, along with insulation stand- ESAUs for selectable effects
been used in conjunction with through- off spacings around the circuit). multiple eFi detonators may be driven
bulkhead initiators (tbi)11. the explosively- simultaneously from a single eSau (such as
driven tbi maintains a pressure bulkhead consequently the integrated Safety &
the twin output configuration shown in
seal into the rocket motor casing, where the arming unit can be reduced significantly in
figure 3) or fired individually from an
explosive shock from the bulkhead septum size and mass, from the nominal 100mm
integrated eSau module comprising
initiates a pyrotechnic material (pyrogen) diameter / 1kg of the eFi-based eSau
multiple independent Firesets; figure 12
chain, to provide a deflagrating (igniferous) module shown in figure 11, down to the
illustrates this multi-point eSau concept in a
output from the tbi. hot-wire initiators have nominal 40mm diameter / 250 grammes of
four-point eFi initiator array.
been used to directly initiate a pyrogen the leeFi-based eSau shown in figure 10.
pellet12, with no intermediate explosive
chain; this arrangement has the advantage
Figure 11. miniature
that minimal mechanical shock is imparted
eSau (left)
into the rocket motor casing by the exploiting a
activation of the ignition module (since compact low-
energy fireset
there is no explosive event), thereby
(centre and right).
simplifying the mechanical design of the
motor casing and enhancing the ignition
reliability of the motor.

this direct initiation approach can also be

evaluated with an eFi initiator within the
pryrogen ignitor, with the eFi ignitor
bringing additional benefits in terms of
insensitivity, ignition reliability, electro-
magnetic immunity and electro-static
discharge resilience13. preliminary work has
demonstrated the direct initiation of
pyrotechnic material using an eFi initiator, to
provide an igniferous output from an igniter
module with no explosive material within
the ignition chain. Figure 10 shows the
arrangement of an eFi Fireset, initiator and
pyrogen pellet, which provided a
160pSi pressure output (into a 20cm3 test
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the small physical size and low mass Conclusion 1 J o’gorman, ‘ebw and eFi detonators – an
advantages of leeFi-based miniature eSaus eFi detonator based systems have overview’, explosives engineering, September
2001, pp. 14-16
lend this technology to networks of demonstrated a step improvement in
independent eSau modules in multi-point operational robustness, reliability and 2 r l beauregard, the history of insensitive
munitions,http://www.insensitivemunitions.or
arrays, with a four-module ‘federated’ array insensitivity in the control and initiation of g/, accessed 22 January 2014
of miniature eSaus depicted in figure 13; energetic systems. the deployment of leeFi
3 S. c. Schmidt, w. l. Seitz & Jerry wackerte, an
both semiconductor-bridge (Scb) based based systems is now enabling these same empirical model to compute the velocity
eSaus and eFi based eSaus can be ‘arrayed’ higher levels of precision, safety and histories of Flyers driven by electrically
as stand-alone modules in this manner15. insensitivity to be applied to a greater range exploding Foils, los alamos Scientific
Simultaneous or phased switching of the (and into smaller calibres) of explosive and laboratory, la-6809, July 1977
multi-point initiator array can determine the pyrotechnic effector systems. 4 r varosh, ‘electric detonators : ebw and eFi’,
propellants, explosives, pyrotechnics, vol. 21,
explosive output characteristics of the host
Further development of these initiator pp. 150-154, 1996
system.
technologies, and the fireset electronics 5 Schlumberger, Secure detonator, november
Further development of the eFi detonator used to control and to drive them, is 2005, accessed 6 February 2014
and Fireset could also provide the basis for bringing forward a range of new techniques http://www.slb.com/~/media/Files
/perforating/product_sheets/wireline_perforat
selectable output from the eFi-based to enable the delivery of selectable effects
ing/secure_detonator.ashx
initiation system itself, allowing the from selected output - with precision and
6 b m coaker, c bell, r J Seddon & J S bower,
commanded detonation or deflagration of with a high level of safety integrity - from ‘miniature triggered vacuum Switches for
the detonator module in order to initiate the the host system. precise initiation of insensitive loads in
desired effect from the platform system; demanding environments’, 39th ieee int. conf.
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Figure 12. multi-point 7 excelitas technologies, blue chip™ detonator,
support a new generation of selectable- initiation sub-system:
effect / selectable-output explosive 2012,http://www.excelitas.com/ downloads
integrated eSau module with
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systems16. leeFi detonator array.
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bulkhead initiator (tbi),http://www.eba-
d.com/products/thru-bulkhead-initiator-tbi/,
accessed 28 January 2014
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Figure 13. multi-point Systems for rocket and guided missile motors,
initiation sub-system: Safety design requirements, Stanag 4368,
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paris, 27-29 november 2013

Simon Bower and Dr Brian Coaker are with e2v

technologies, based in the United Kingdom.
http://www.e2v.com/
Further information: Brian.Coaker@e2v.com

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