Search Results (106)

To enhance critical infrastructure protection against low-cost UAV impacts, this study proposes a novel ring lattice sandwich structure (RLSS) fabricated via an economical interlocking-assembly-brazing method. Its quasi-static compressive behavior is systematically investigated through experiments, numerical simulations, and theoretical analysis. Theoretical models for relative density and initial yield stress are validated against experiments, with errors of 7.1% and 6.6%, respectively. Quasi-static tests show that the one-layer RLSS exhibits a specific energy absorption (SEA) of 8.67 J/g, while the two-layer structure drops to 5.66 J/g due to inter-layer torsional instability. SHPB impact tests at strain rates of 750–1369 s⁻¹ demonstrate a pronounced strain-rate effect, with dynamic increase factors ranging from 1.14 to 1.43. Numerical simulations accurately reproduce the experimental deformation modes and reveal that multi-layer (2–5 layers) RLSSs reduce SEA by 46.9% compared with the one-layer simulated value of 9.43 J/g. Adding a 0.3-mm inner panel in simulations restores the crushing mode and raises the SEA of the two-layer structure to 7.19 J/g, surpassing the non-panel counterpart (6.03 J/g). Hybrid core configurations provide additional advantages: Mode I (ring–pyramid with inner panel) enhances total energy absorption with a limited ring-layer count, while Mode II (alternating layers) achieves minimal plateau stress fluctuation (PSF = 0.09). These findings confirm that the proposed RLSS, especially when optimized with thin inner panels or hybrid designs, offers great potential as protective cladding against impact and blast threats. Full article

Weak interlayers in layered rock masses can strongly influence stress-wave propagation, crack development, block motion, and flyrock behavior during bench slope blasting. To clarify the controlling mechanisms, a quasi-two-dimensional single-hole bench-slope model containing a weak interlayer was established using a continuous-discontinuous element method. Three single-factor groups were designed to examine the effects of interlayer thickness, dip angle, and wave impedance on the dynamic response of the slope. The results show that the weak interlayer acts as a geometric and dynamic symmetry-breaking interface. Relative to the locally quasi-radial response around the centrally initiated charge, interface reflection, transmission, and local dissipation produce direction-dependent stress, velocity, crack, and displacement fields. Interlayer thickness controls the spatial extent of this asymmetric response, dip angle determines its preferred direction, and wave impedance governs its dynamic intensity through unequal energy partition across the interface. Within the respective single-factor analyses, relatively larger flyrock responses were observed for the cases with a 2.0 m interlayer thickness, a 70° dip angle, and a low-wave-impedance interlayer. These observations represent comparative trends within the present quasi-two-dimensional single-hole model and should not be regarded as direct predictions of field-scale flyrock risk or a verified combined unfavorable blasting condition. These findings indicate that weak-interlayer geometry and mechanical contrast play important roles in controlling asymmetric blasting responses. Within the assumptions of the present quasi-two-dimensional single-hole model, the results provide mechanistic insights into relative response trends rather than direct field-scale blasting predictions. Full article

Protective reinforced-concrete (RC) elements designed to resist contact blast loading must reconcile high energy dissipation with material and weight efficiency. This study examines HollowHex, an RC slab architecture in which periodic hexagonal cellular voids redistribute blast-induced stresses along inclined web-walls through a Vierendeel-type framing action. A full-factorial design of experiments across web thickness, charge mass, and hexagonal cell radius was carried out with Abaqus/Explicit using a concrete-damaged-plasticity model and mass-dependent Friedlander overpressure histories calibrated to UFC 3-340-02 scaled-distance relations. A six-level mesh-convergence study with three independent fine-mesh verification runs established the residual mesh effect as regime-dependent, bounded within approximately 13% in the elastic and severe-damage regimes and approximately 18% in the transition regime. Ten surrogate-model families—linear, polynomial, kernel, ensemble, and multilayer-perceptron—were benchmarked under leave-one-out, 5-fold, and 7-fold cross-validation. The best models achieved out-of-sample R² = 0.96 for peak displacement and R² = 0.93 for a continuous damage volume ratio (DVR), with train-to-validation gaps of only 0.03 and 0.06, indicating genuine generalization on the small dataset. A direct identical-condition comparison against circular-hollow slabs of matched void area shows blast-equivalent performance across the elastic, transition, and severe damage regimes (peak displacements within 2%, damage volume ratios within 7%), positioning the hexagonal architecture as a blast penalty-free alternative whose selection can be driven by non-blast criteria. A cross-validated parametric design heatmap is provided as a screening tool within the verified envelope. The uniform loading idealization is cross-checked against the spatially resolved CONWEP model, conservative on peak displacement by a factor of approximately 3.5, while approximately damage-equivalent and the constitutive model is validated at the damage level against documented contact-explosion tests through coupled FEM–SPH simulation. The findings position HollowHex not as a universally superior geometry but as a quantitatively beneficial alternative within the service/transition design range of greatest practical interest for blast protection. Full article

Conventional valorization of blast furnace slag commonly involves granulation, fine grinding, mechanical activation, or chemical activation, which increase energy demand and processing complexity. This study investigated a minimally processed blast furnace slag (MP-BFS), defined here as the fraction passing 64 µm obtained by sieving a 0–8 mm industrial material without grinding, additional granulation, thermal treatment, or chemical activation. MP-BFS replaced 10–50% of the cement by mass to reduce clinker in industrial mortars formulated at a constant flow spread of 23–24 cm and tested from 8 h to 90 d. Bulk density, water-accessible porosity, total and capillary water absorption, and compressive and flexural strengths were evaluated. Replacing 10% of the cement with slag improved compressive strength from the earliest test age and increased the 28-day compressive and flexural strengths by 5.1% and 9.5%, respectively, relative to the control mortar; this response coincided with a reduction in measured porosity from 8.95% to 8.01%. This improvement is consistent with a physical filling effect and improved particle packing, although these mechanisms were not directly verified by microstructural analyses. At higher replacement levels, water-accessible porosity increased, reaching 24.45% at 50% slag replacement, alongside greater water ingress and delayed strength development. Exploratory empirical regression analyses described associations among slag content, porosity, water transfer, and compressive strength within the investigated formulations. A simplified screening-level constituent-production-and-transport comparison per cubic meter, based on generic ICE factors and an assumed 50 km transport distance, estimated a maximum embodied carbon reduction of 44% at 50% replacement. Curing energy, use, carbonation, maintenance, and end-of-life stages were excluded. Overall, 10% MP-BFS replacement provided the most favorable performance–carbon content balance, whereas 30–50% achieved larger carbon reductions but showed early-age strength losses that limit their suitability for rapid-demolding applications under the investigated conditions. Full article

In this study, the thermodynamic conditions governing TiC formation were systematically investigated based on Gibbs free energy and interaction parameter theory. The effects of temperature and furnace atmosphere on interaction parameters were explicitly incorporated, enabling an improved thermodynamic description of TiC formation under realistic blast furnace conditions. Furthermore, compared with conventional two-dimensional equilibrium analyses, a three-dimensional Ti-C-temperature thermodynamic precipitation surface was established to quantitatively evaluate the effects of temperature, titanium content, and carbon content on TiC precipitation behavior. The results indicate that titanium is the dominant controlling factor for TiC formation, while carbon plays a secondary synergistic role. Compared with dissolved carbon, solid carbon provides more favorable thermodynamic conditions, suggesting that TiC preferentially forms via interactions with high-activity carbon sources such as coke or refractory materials. Based on the modified thermodynamic framework and boundary conditions, a quantitative precipitation criterion was established as 100 × w[Ti]_% + w[C]_% ≥ 10, which ensures TiC precipitation prior to molten iron solidification under representative blast furnace hearth conditions. The proposed criterion provides a practical guideline for titanium addition and carbon regulation in blast furnace ironmaking and improves the thermodynamic prediction capability for titanium-bearing protective phase formation in complex high-temperature metallurgical environments. Full article

High-voltage self-blast circuit breakers feature complex gas flow field dynamics during the arc interruption process due to the multiple gas chambers and valves in the interrupter. The structure of key interrupter components and the characteristics of the operating mechanism significantly influence the gas flow field behavior, thereby affecting the breaking performance. The C₄F₇N gas mixture is currently the most promising alternative to SF₆. However, the influence mechanisms of various factors on its breaking performance remain unclear, which limits the design of C₄F₇N-based self-blast interrupter chambers. This paper investigates the impact of nozzle throat length and mechanism stroke on the breaking performance of a 126 kV double-motion self-blast circuit breaker prototype by establishing a magnetohydrodynamic (MHD) arc model for C₄F₇N gas mixtures. The results indicate that a longer throat length can enhance the pressure-buildup capability in the expansion chamber to some extent, but its effect on short arcing times is limited, whereas it has a more pronounced influence on medium and long arcing times. However, it also impedes arc energy dissipation, potentially reducing the breaking capability for short and medium arcing times while improving performance for long arcing times. A larger mechanism stroke not only ensures a greater contact gap at current zero for long arcing times but also accelerates the gas flow velocity between the contacts, facilitating arc energy dissipation and enhancing the thermal interruption performance. Full article

Comminution is the most energy-intensive stage in mineral processing and a major source of indirect greenhouse gas (GHG) emissions in mining. This study evaluates the impact of Ultra-High-Intensity Blasting (UHIB) on downstream comminution energy demand and associated GHG emissions under conditions representative of large-scale Chilean mining. Fragmentation from conventional blasting and UHIB was simulated using JKSimBlast, and the resulting particle size distributions were used as input for four comminution circuit configurations modeled in JKSimMet. Two ore hardness scenarios were analyzed: hard ore (Bond Work Index, BWI = 19 kWh/t) and soft ore (BWI = 11 kWh/t). Power draw of crushers and mills was used to estimate specific energy consumption and GHG emissions based on the Chilean electrical system emission factor. Results show that UHIB enables significant reductions in comminution energy demand, reaching approximately 18% for hard ore and over 30% for soft ore. These reductions are primarily associated with circuit simplification, including the removal of energy-intensive stages such as primary crushing and SAG milling. The results demonstrate that improved fragmentation can reduce downstream energy demand and carbon intensity, highlighting UHIB as an effective mine-to-mill strategy for energy efficiency and emission reduction. Full article

The depletion of global reserves of high-quality sulfide nickel deposits, coupled with the steady growth of nickel demand, has led to increased interest in the processing of oxidized (lateritic) nickel ores, including deposits with significant resource potential in the Republic of Kazakhstan. This paper provides an overview of global nickel ore reserves and their distribution, as well as the major nickel deposits in Kazakhstan, which are primarily located in the Aktobe, East Kazakhstan, Kostanay, and Pavlodar regions. Pyrometallurgical processing routes for lateritic nickel ores are also considered. Conventional production technologies, including the Rotary Kiln–Electric Furnace (RKEF), Krupp–Renn process, blast furnace smelting, Vaniukov process, and ISASMELT process, are reviewed, and their process flow diagrams are presented. These methods typically process lateritic nickel ores containing more than 1.2% Ni, whereas Kazakhstan ores are characterized by lower nickel grades, generally in the range of 0.75–1.1%. The advantages and limitations of conventional processing routes are analyzed, and the factors limiting the effective beneficiation of lateritic nickel ores using traditional methods are identified. The present study substantiates the feasibility of producing nickel-containing alloys from lateritic nickel ores using a metallothermic reduction approach. This method is based on the reduction of nickel and iron oxides using metallic reductants, which enables more selective extraction of target components and the formation of alloys with controlled composition. Metallothermic reduction is of particular interest for the processing of low-grade lateritic ores, as it allows the production of nickel-containing alloys without prior beneficiation, at lower energy consumption, and with reduced sensitivity to variations in the chemical and mineralogical composition of the raw materials. Therefore, this approach is considered a promising direction for the processing of lateritic nickel ores in Kazakhstan. Full article

Aiming at cemented tailings backfill (CTB) damage and collapse induced by secondary stope blasting in the sublevel open stoping with a subsequent filling method, a new CTB damage control technology termed “Synergistic Utilization of Cumulative Blasting Damage (SU-CBD)” is proposed. First, theoretical analysis is conducted to reveal the influence mechanism of rock mass damage accumulation on its blastability, verifying the feasibility of the SU-CBD technology. Subsequently, based on the LS-DYNA R11.1 software and RHT material model, a numerical model is established, and the small restart technique is adopted to realize the continuous simulation of multi-row blasting. By comparing the rock mass fragmentation ratio, energy distribution, and CTB damage degree among different charge structure schemes, the optimal charge structure combination is obtained. To address the issues of retained rock mass damage and overbreak caused by multiple blasting operations, a dynamic adjustment method for blasthole row spacing is proposed, with the optimal row spacing increment determined as 1.0 m. To verify the technical effectiveness, field industrial tests are carried out in Stope No. 5 of the 4500 m–4550 m mining level in the Bangzhong Zinc-Copper Mine. The results show that the optimized blasting scheme keeps the CTB intact without collapse and achieves uniform ore fragmentation, and the oversize ore ratio (particle size > 50 cm) is only 2.4%, with the numerical simulation results in good agreement with the field test results. The research indicates that the SU-CBD technology can effectively reduce the powder factor and CTB blasting damage while ensuring the blasting fragmentation effect, providing reliable blasting design support for the secondary stope. Full article

The growing global demand for mineral resources is challenging mining operations to maintain productivity while processing lower-grade ores and increasingly complex deposits. This study presents an integrated framework that leverages machine learning (ML) and high-fidelity simulation to model and support scenario-based decision-making for the blasting–crushing–SAG (Semi-Autogenous Grindin) milling chain using a calibrated flowsheet. Using publicly available data from the Barrick Cortez Mine (Nevada, USA), more than three million operational scenarios were generated using the Integrated Extraction Simulator (IES) to capture system variability and sensitivity. Machine learning meta-models, built using Random Forest and XGBoost methods, were trained on the simulated data and achieved coefficients of determination (R²) exceeding 0.90 across all key outputs, including P20, P50, P80, and mass flow rates at different operational stages. The meta-models accurately reproduced plant-scale behaviour while reducing computational requirements by several orders of magnitude compared with full-scale simulations. SHapley Additive exPlanations (SHAP) analysis revealed that blast-hole diameter, explosive energy parameters, screen cut-size, crusher feed characteristics, and SAG mill operating conditions are the dominant factors impacting downstream particle size distributions. The proposed framework enables near-real-time evaluation of “what-if” operational scenarios and provides transparent, quantitative decision-support for integrated mine-to-mill optimisation. Full article

Frequent rockbursts in staggered roadways beneath residual coal pillars pose a critical challenge for the slice mining of ultra-thick coal seams. Taking the LW250101-2 of Huating Coal Mine as a case study, this paper systematically reveals the stress evolution laws and rockburst mechanism induced by irregular residual pillars by integrating microseismic (MS) monitoring, moment tensor inversion, and numerical simulation. First, source mechanism inversion analysis elucidated that compressive-shear failure of coal pillars was the dominant rupture mode in five of the eight recorded rockburst events. Second, numerical simulations demonstrate that the width of the left wing and the thickness of the right wing of the “L-shaped” coal pillar structure are the key geometric factors controlling rockburst risk; larger dimensions correlate with more intense stress concentration and higher-energy MS events. Moreover, the stress deflection effect of “L-shaped” coal pillars causes the haulage gateway of the LW250101-2 to remain in a state of stress accumulation, increasing its susceptibility to rockburst. Finally, a synergistic prevention system consisting of deep-hole roof blasting, large-charge coal blasting, and ultra-deep large-diameter boreholes was implemented. Field monitoring confirms that these measures dissipated high-stress concentrations, reduced rockburst frequency to zero and ensured safe mining. Full article

Optimizing the blast energy distribution is crucial for enhancing rock fragmentation, minimizing overexcavation, and boosting profitability in mining operations. This study introduces a theoretical model to predict the blasting Energy Factor ${(\mathrm{F}}_{\mathrm{e}})$ in mining tunnels, based on the Cracking Energy ${(\mathrm{E}}_{\mathrm{g}})$ of the rock mass, derived from the deformation energy of brittle materials (Young’s modulus) and adjusted by the Rock Mass Rating (RMR). The model was validated using 42 blasting datasets from horizontal galleries at El Teniente mine, Chile. Data included geometric parameters (tunnel sections, drilling length, diameter, number of holes, meters drilled), explosive type and consumption, and geomechanical properties, particularly the RMR. Results show that as rock mass quality improves (higher RMR), both ${\mathrm{F}}_{\mathrm{e}}$ and $\%{\mathrm{E}}_{\mathrm{g}}$ increase, more competent rock masses require higher input energy to initiate and propagate cracks, and a greater portion of that energy is effectively utilized for crack formation. For instance, rock masses with an RMR of 66 exhibited an average ${\mathrm{F}}_{\mathrm{e}}$ of 7.62 MJ/m³ and $\%{\mathrm{E}}_{\mathrm{g}}$ of 4.8%, while those with an RMR of 75 showed higher values (${\mathrm{F}}_{\mathrm{e}}$ = 8.47 MJ/m³, $\%{\mathrm{E}}_{\mathrm{g}}$ = 6.4%). This confirms that less fractured rock masses require higher ${\mathrm{F}}_{\mathrm{e}}$ and $\%{\mathrm{E}}_{\mathrm{g}}$ for effective fragmentation. Lithology also plays a significant role in energy consumption. Diorite displayed the highest ${\mathrm{F}}_{\mathrm{e}}$ (8.34 MJ/m³) and higher efficiency ($\%{\mathrm{E}}_{\mathrm{g}}$ = 7.0%), whereas andesite showed lower ${\mathrm{F}}_{\mathrm{e}}$ (7.61 MJ/m³) and lower crack propagation efficiency ($\%{\mathrm{E}}_{\mathrm{g}}$ = 3.7%). Unlike traditional ${\mathrm{F}}_{\mathrm{e}}$ prediction methods, which rely solely on explosive data and excavation volume, this model integrates RMR, enabling more precise energy allocation and fostering sustainable mining practices. This approach enhances decision-making in blast design, offering a more robust framework for optimizing energy use in mining operations. Full article

Joints and other discontinuities in rock masses cause overbreak, underbreak, and instability during tunnel blasting. This paper reviews recent advances in damage control for jointed rock tunnels and validates key findings through numerical simulations. At the microscale, joints affect stress wave propagation, energy distribution, and crack growth patterns. We used ANSYS/LS-DYNA 19.0 to simulate 16 parametric cases and quantify the effects of joint geometry on blasting response. Results show that joint-to-borehole distance is the primary factor controlling damage distribution. A joint dip angle of 45° produces the most severe damage anisotropy, with cracks propagating preferentially along the joint plane. A three-dimensional tunnel model was then developed to assess water-pressure blasting. Compared with conventional methods, water-pressure blasting reduces damage depth by 20.4% and peak particle velocity by 57.6% in jointed rock. The paper also discusses parameter optimization methods, intelligent evaluation techniques, and dynamic control strategies. Engineering recommendations are provided for different geological conditions, including horizontally layered rock, inclined joints, and deep high-stress environments. This work offers both theoretical insights and practical guidance for precision blasting in jointed rock tunnels. Full article

Although the dynamic response of orthotropic materials under uniaxial impact loading has been extensively studied, their behavior under multiaxial stress states, which more accurately represent real-world blast and impact scenarios, has received limited attention. To address this gap, this study employed a self-developed biaxial impact testing apparatus to systematically investigate the dynamic mechanical behavior of beech wood, a typical orthotropic material, under three biaxial loading configurations: radial-tangential, radial-longitudinal, and tangential-longitudinal. By combining theoretical derivation with experimental data, it systematically examines stress wave propagation characteristics, strain rate effects, and anisotropy evolution under different loading paths. The results reveal that beech wood exhibits significantly distinct dynamic responses along different material orientations, with a consistent strength hierarchy: longitudinal > radial > tangential. Biaxial loading notably enhances the equivalent stress–strain response and alters the deformation mechanisms and energy absorption behavior. Furthermore, lateral confinement and multiaxial stress coupling are identified as critical factors influencing the dynamic performance. This study provides the first systematic revelation of the strain rate strengthening mechanisms and wave propagation characteristics of orthotropic materials from the perspective of multiaxial dynamic loading, thereby offering theoretical and experimental foundations for developing advanced dynamic constitutive models suitable for complex impact conditions. These findings provide important guidance for the design and evaluation of lightweight impact-resistant structures in fields such as aerospace and protective engineering. Full article

Blast damage to structural members poses serious risks to both buildings and people, making it important to understand how these elements behave under extreme loads. Columns in reinforced concrete (RC) structures are especially critical, as their sudden failure can trigger progressive collapse, unlike beams or slabs that have more redundancy. This state-of-the-art review brings together the current knowledge of the blast response of RC columns, focusing on their failure patterns, dynamic behavior, and key loading mechanisms. The studies covered include experiments, high-fidelity numerical simulations, emerging machine learning approaches, and analytical models for columns of different shapes (square, rectangular, circular) and strengthening methods, such as fiber reinforcement, steel-concrete composite confinement, and advanced retrofitting. Composite columns are also reviewed to compare their hybrid confinement and energy-absorption advantages over conventional RC members. Over forty specific studies on RC columns were analyzed, comparing the results based on geometry, reinforcement detailing, materials, and blast conditions. Both near-field and contact detonations were examined, along with factors like axial load, standoff distance, and confinement. This review shows that RC columns respond very differently to blasts depending on their shape and reinforcement. Square, rectangular, and circular sections fail in distinct ways. Use of ultra-high-performance concrete, steel fibers, steel-concrete composite, and fiber-reinforced polymer retrofits greatly improves peak and residual load capacity. Ultra-high-performance concrete can retain a significantly higher fraction of axial load (often >70%) after strong blasts, compared to ~40% in conventional high-strength RC under similar conditions. Larger sections, closer stirrups, higher transverse reinforcement, and good confinement reduce spalling, shear failure, and mid-height displacement. Fiber-reinforced polymer and steel-fiber wraps typically improve residual strength by 10–15%, while composite columns with steel cores remain stiff and absorb more energy post-blast. Advanced finite element simulations and machine learning models now predict displacements, damage, and residual capacity more accurately than older methods. However, gaps remain. Current design codes of practice simplify blast loads and often do not account for localized damage, near-field effects, complex boundary conditions, or pre-existing structural weaknesses. Further research is needed on cost-effective, durable, and practical retrofitting strategies using advanced materials. This review stands apart from conventional literature reviews by combining experimental results, numerical analysis, and data-driven insights. It offers a clear, quantitative, and comparative view of RC column behavior under blast loading, identifies key knowledge gaps, and points the way for future design improvements. Full article