Search Results (21)

Modern energetic materials (EMs) have many different civil applications. One of their most promising applications in civil engineering is explosive hardening, which facilitates the fast and cost-effective improvement of mechanical properties in the treated material. In this work, we present the results of our investigation on the explosive hardening of S235JR Steel with PBX formulations containing silicone binders and 1,3,5-trinitro-1,3,5-triazinane (RDX). In terms of safety, the impact (5–15 J) and friction (240–360 N) sensitivity of the tested plastic-bonded explosives (PBXs) was verified, simultaneously with DSC tests, energy of activation calculations, and critical diameter measurement. The developed material, prepared with techniques similar to the anticipated working conditions, is characterized by a high detonation velocity (up to 7300 m/s), low sensitivity for mechanical factors (10 J, 288 N), and a small critical diameter (3.3 mm). The developed PBX based on a silicone binder demonstrated grain fragmentation, recrystallization, and an increase in the surface hardness of S235JR steel, which was confirmed with SEM, EBSD, microstructure analysis, and microhardness studies. Full article

The paper deals with the evaluation of the quality of Cu-Al-AlMg3 structural transition joints (STJ) made by explosion welding proposed for the renovation of galvanizer hangers. The three-layer joint consisted of electrolytic copper with a thickness of 25 mm, 2 mm of aluminium represented by the AW1050 alloy, and 25 mm of the EN AW 575 aluminium alloy. Light microscopy analysis confirmed the wavy pattern of both interfaces of the welded joint and significant plastic deformation in close proximity to the waves. Microhardness measurement revealed a partial strain hardening of the AW5754 copper-aluminium alloy near the interface and a significant increase in microhardness in the vortex zone of waves, reaching a value of up to 863 HV 0.025. Microcracks were also observed in these places. The intermetallic phase Al₂Cu was identified in the vortex zones by XRD analysis. As a continuous layer of intermetallic phase was not observed in the interface of the welded joint, it is possible to consider the used welding parameters as appropriate. A semi-quantitative EDX analysis revealed a diversity of chemical composition in the vortex zones, which does not correspond to the phase composition based on the equilibrium binary Al-Cu diagram due to non-equilibrium conditions in the formation of the welded joint interface. The bond strength of three-layer welded joint evaluated by the strength test ranged from 151 to 171 MPa, which represented approximately a two-fold increase in comparison to the ultimate tensile strength of alloy AW1050, while the failure occurred in all samples at the AW1050-AW5754 alloy interface. Full article

In this paper, the microstructure and mechanical properties at the interface of Incoloy825/X65 bimetallic composite pipe achieved by explosive welding were systematically studied. Results show that a periodic wavy bonding interface was formed between the Incoloy825 and X65 due to the jets caused by the high-impact stresses during explosive welding, which was beneficial for improving the bonding strength of the Incoloy825 and X65. Atomic diffusion and localized melting occurred near the interface during explosive welding. Some fine crystal grains were generated in the vicinity of the interface due to the strong plastic deformation and dynamic recrystallization, whereas some elongated grains growing in the perpendicular direction to the interface were found in the wider localized melted zone. Room temperature nanoindentation test showed that due to the existence of fine grains resulting from the recrystallization at the interface, the hardness of the interface was higher than that of the base metals. Voids and defects were prone to appearing in the vortex regions near the interface, where the weak point in the interface was located. Full article

The titanium/aluminum composite materials overcome the limitations of single metal materials and achieve lightweight, high-strength, and corrosion-resistant properties. However, there have been no reports on explosion-welded composites of titanium alloys and seven-series aluminum alloys. Therefore, TA1/Al1060/Al7075 explosion-welded plates with three different explosive thicknesses were successfully prepared using Al1060 as the transition layer. The SPH-FEM coupled algorithm was employed to analyze the detonation process in detail and predict the interface under different explosive thicknesses. The results showed that during the explosion welding process, the high temperature, pressure, and high-speed impact resulted in significant plastic deformation and jetting phenomena at the bonding interface, which were in good agreement with the experimental observations. With the increase in explosive thickness, the TA1/Al1060 bonding interface exhibited a flat shape, while the Al1060/Al7075 interface transitioned from a flat to a wavy morphology. Moreover, the crack, vortex, and TiAl₃ were observed at the interface. Mechanical testing results revealed that the composite plate with a 35 mm explosive thickness exhibited the best tensile, shear, and bending performance, indicating the optimal process parameter. This study provides significant support and reference for the application of explosion welding technology in titanium alloys and seven-series aluminum alloy composite materials. Full article

The increasingly harsher and more complex international and European environmental legislation drives the current development of “greener” energetics materials and munitions. The aerospace and defense industries rely on extensive research in the formulation and scale-up production of polymer-bonded explosives (PBX). In this context, this paper aims to present a versatile method for obtaining “green” PBX formulations based on two high explosives (hexogen (RDX) and octogen (HMX)) and acrylic acid—ethyl acrylate copolymeric binders. This study developed an innovative “eco-friendly” technology for coating the RDX and HMX crystals, allowing straightforward and safer manufacture of PBX, avoiding the use of traditional organic solvents. At the same time, these polymeric binders are soluble in water at a slightly alkaline pH and insoluble at acidic or neutral pH, thus ensuring a safer manipulation of the energetic materials during their entire life cycle and a facile recovery of the explosive in its original shape and morphology in demilitarization. The PBX formulations were characterized via specific analytical tools to evaluate the influence of their composition on the safety and performance characteristics: scanning electron microscopy (SEM), Fourier-transform infrared spectroscopy (FT-IR), alkaline pH solubility tests, differential thermal analysis (DTA), impact sensitivity test (BAM Fall Hammer Test), friction sensitivity test (BAM Friction Test), electrostatic sensitivity test (ESD), vacuum stability test, small scale shock reactivity test (SSRT), detonation velocity test. The “green” PBX formulations obtained through a simple and innovative coating method, based on the polymeric binders’ adjustable water solubility, demonstrated remarkable energetic performances and a facile recovery of the explosive crystals by the dissolution of the polymeric binder at pH 11 and 30 °C. Full article

During the explosive welding, the bonding interface of welded materials was fast heated due to high strain rate and drastic plastic deformation. The periodical wave interface, with an amplitude of ~300 μm and a period wavelength of ~800 μm, was identifiable as a uniform wave interface formed in the bonding interface. The details of the formation of melting zone and mixing zone of welding materials at the interface were observed. Combined with the Ti-Fe binary phase diagram and the principle of diffusion welding, the phase composition and evolution process of the melting and mixing zone of the bonding interface were investigated by transmission electron microscopy (TEM) and energy dispersive spectrometer (EDS). Significance of the intermetallic compound was found in the mixing zone and melting zone, which was mainly TiFe, TiFe₂, TiO₂, Fe₂O₃ and some other intermetallic oxides. Meanwhile, the phenomenon of the titanium agglomeration and oxygen precipitation was observed in the melting zone. The bonding interface could be determined as a mixing welding of mechanical mixing, melting, diffusion and solidification that occurred in the mixing zone, and melting welding and diffusion welding mainly occurred in the melting region. Full article

A copper/Q235 steel/copper composite block with excellent bonding interfaces was prepared by explosive welding which was a promising technique to fabricate laminates. The microstructure and mechanical properties of the interfaces were investigated via the tensile-shear test, optical microscope (OM), X-ray diffraction (XRD), scanning electron microscope (SEM), and electron back-scattered diffraction (EBSD). The results showed that the shear strength of the upper-interface and lower-interfaces of the welded copper/steel are higher than ~235 MPa and ~222 MPa, respectively. The specimens failed fully within the copper and not at the bonding interface. It was attributed to: (1) no cavities and cracks at the interface; (2) the interface formed a metallurgical bonding including numerous ultra-fine grains (UFGs) which can significantly improve the plastic deformation coordination at the interface and inhibit the generation of micro-cracks. Full article

In this investigation, three different explosive materials have been used to improve the properties of titanium grade 2: ammonal, emulsion explosives, and plastic-bonded explosives. In order to establish the influence of explosive hardening on the properties of the treated alloys, tests were conducted, including microhardness testing, microstructure analysis, and tensile and corrosion tests. It has been found that it is possible to achieve a 40% increase in tensile strength using a plastic explosive (PBX) as an explosive material. On the other hand, the impact of the shock wave slightly decreased the corrosion resistance of titanium grade 2. The change in corrosion rate is less than 0.1µm/year, which does not significantly affect the overall corrosion resistance of the material. The reduction in corrosion resistance is probably due to the surface geometry changes as a result of explosive treatment. Full article

Plastic-bonded explosives (PBXs) consisting of explosive grains and a polymer binder are commonly synthesized to improve mechanical properties and reduce sensitivity, but their intrinsic chemical behaviors while subjected to stress are not sufficiently understood yet. Here, we construct three composites of β-HMX bonded with the HTPB binder to investigate the reaction characteristics under shock loading using the quantum-based molecular dynamics method. Six typical interactions between HMX and HTPB molecules are detected when the system is subjected to pressure. Although the initial electron structure is modified by the impurity states from HTPB, the metallization process for HMX does not significantly change. The shock decompositions of HMX/HTPB along the (100) and (010) surface are initiated by molecular ring dissociation and hydrogen transfer. The initial oxidations of C and H within HTPB possess advantages. As for the (001) surface, the dissociation is started with alkyl dehydrogenation oxidation, and a stronger hydrogen transfer from HTPB to HMX is detected during the following process. Furthermore, considerable fragment aggregation is observed, which mainly derives from the formation of new C−C and C−N bonds under high pressure. The effect of cluster evolution on the progression of the following reaction is further studied by analyzing the bonded structure and displacement rate. Full article

Polysiloxanes are reviewed for their properties depending on the functionalization of a silicon–oxygen backbone chain. Next, the properties were referred to the requirements that polymers used in plastic/polymer-bonded explosive (PBX)-type explosives must meet. Finally, the current state and prospects for the implementation of polysiloxanes in plastic/polymer-bonded explosive (PBX) formulations are presented. Full article

Microstructural characterization of composite high explosives (HEs) has become increasingly important over the last several decades in association with the development of high fidelity mesoscale modeling and an improved understanding of ignition and detonation processes. HE microstructure influences not only typical material properties (e.g., thermal, mechanical) but also reactive behavior (e.g., shock sensitivity, detonation wave shape). A detailed nondestructive 3D examination of the microstructure has generally been limited to custom-engineered samples or surrogates due to poor contrast between the composite constituents. Highly loaded (>90 wt%) HE composites such as plastic-bonded explosives (PBX) are especially difficult. Here, we present efforts to improve measurement quality by using single and dual-energy microcomputed X-ray tomography and state-of-the-art image processing techniques to study a broad set of HE materials. Some materials, such as PBX 9502, exhibit suitable contrast and resolution for an automatic segmentation of the HE from the polymer binder and the voids. Other composite HEs had varying levels of success in segmentation. Post-processing techniques that used commercially available algorithms to improve the segmentation quality of PBX 9501 as well as zero-density defects such as cracks and voids could be easily segmented for all samples. Aspects of the materials that lend themselves well to this type of measurement are discussed. Full article

In this work, an improved explosive welding technique was investigated to fabricate a thin Mg/Al plate, where an additional thin aluminum sheet was used as a buffer layer between the explosive and the Al plate, and the Mg plate was rigidly constrained by a steel plate to avoid excessive deformation. Moreover, the welding parameters were optimized using theoretical analysis and numerical simulation, and the interfacial behavior was simulated using the SPH method. The bonding properties of the achieved joints were investigated using microstructure observation and mechanical tests. It was concluded that this technique is an effective method for producing a thin Mg/Al composite plate. In both morphology observation and mechanical tests, an excellent bonding quality was confirmed. In addition, smoothed particle hydrodynamics (SPH) simulation revealed an extreme condition of local high temperature and plastic strain in the welding process, and the characteristic parameters of waves obtained using simulation are well congruous with the experiment. Full article

Cellulose acetate butyrate (CAB) is a widely used binder in polymer bonded explosives (PBXs). However, the mechanical properties of PBXs bonded with CAB are usually very poor, which makes the charge edges prone to crack. In the current study, seven plasticizers, including bis (2,2-dinitro propyl) formal/acetal (BDNPF/A or A3, which is 1:1 mixture of the two components), azide-terminated glycidyl azide (GAPA), n-butyl-N-(2-nitroxy-ethyl) nitramine (Bu-NENA), ethylene glycol bis(azidoacetate) (EGBAA), diethylene glycol bis(azidoacetate) (DEGBAA), trimethylol nitromethane tris (azidoacetate) (TMNTA) and pentaerythritol tetrakis (azidoacetate) [PETKAA], were studied for the plasticization of CAB. Molecular dynamics simulation was conducted to distinguish the compatibilities between CAB and plasticizers and to predict the mechanical properties of CAB/plasticizer systems. Considering the solubility parameters, binding energies and intermolecular radical distribution functions of these CAB/plasticizer systems comprehensively, we found A3, Bu-NENA, DEGBAA and GAPA are compatible with CAB. The elastic moduli of CAB/plasticizer systems follow the order of CAB/Bu-NENA>CAB/A3>CAB/DEGBAA>CAB/GAPA, and their processing property is in the order of CAB/Bu-NENA>CAB/GAPA>CAB/A3>CAB/DEGBAA. Afterwards, all the systems were characterized by FT-IR, differential scanning calorimetry (DSC), differential thermogravimetric analysis (DTA) and tensile tests. The results suggest A3, GAPA and Bu-NENA are compatible with CAB. The tensile strengths and Young’s moduli of these systems are in the order of CAB/A3>CAB/Bu-NENA>CAB/GAPA, while the strain at break of CAB/Bu-NENA is best, which are consistent with simulation results. Based on these results, it can be concluded that A3, Bu-NENA and GAPA are the most suitable plasticizers for CAB binder in improving mechanical and processing properties. Our work has provided a crucial guidance for the formulation design of PBXs with CAB binder. Full article

Glycidyl azide polymer (GAP), an energetic binder, is the focus of this review. We briefly introduce the key properties of this well-known polymer, the difference between energetic and non-energetic binders in propellant and explosive formulations, the fundamentals for producing GAP and its copolymers, as well as for curing GAP using different types of curing agents. We use recent works as examples to illustrate the general approaches to curing GAP and its derivatives, while indicating a number of recently investigated curing agents. Next, we demonstrate that the properties of GAP can be modified either through internal (structural) alterations or through the introduction of external (plasticizers) additives and provide a summary of recent progress in this area, tying it in with studies on the properties of such modifications of GAP. Further on, we discuss relevant works dedicated to the applications of GAP as a binder for propellants and plastic-bonded explosives. Lastly, we indicate other, emerging applications of GAP and provide a summary of its mechanical and energetic properties. Full article

A microstructure finite element method combining the cohesive zone model (CZM) is used to simulate the mechanical behavior, deformation, and failure of polymer-bonded explosive (PBX) 9501 under quasi-static loading. PBX 9501 consists of Cyclotetramethylene tetranitramine (HMX) filler particles with a random distribution packaged in a polymeric binder. The particle is treated as elastic and the binder as viscoelastic. Cohesive elements with a bilinear softening law are inserted into the particle/binder interface, the HMX particle, and the binder to study the interface’s debonding and failure evolution. Macroscopic stress–strain curves homogenized across the microstructure under tension and compression with different strain rates are basically consistent with the experimental data. The interface debonding approximately vertical to the loading direction is the primary failure mechanism under tension, while shear failure along the interfaces and particle fracture plays a significant role under compression. The effects of interface strengths and strain rates on the performance of PBX 9501 are also evaluated. The tensile and compressive strengths are dependent on the interface strength and strain rate, but the failure paths are insensitive. This model is shown to accurately predict macroscopic responses and improve our understanding of the relationship between the mechanical behavior and microstructure of PBX 9501. Full article