The slurry process for producing plastic bonded explosives (PBX) has been used for many years. However, until recently the mechanisms involved have not been studied quantitatively to determine the effects of the various control variables. Recently, the effects of operating variables on the final product have been studied; however, no attempt was made to measure particle growth during the slurry process. This study applies an image analysis tool to measure particle size distributions (PSDs) during the slurry process to produce PBX 9501, a specific formulation used in nuclear weapons. The observed PBX 9501 slurry behavior leads away from the typical population balance description of agglomeration, that is, a discrete particle-particle coalescence mechanism. The behavior observed in these experiments indicates that the initial state of the system contains a number of smaller particles clustered together. The cluster then coalesces into a large particle as solvent is removed and the slurry continuously mixed. Other small fragments are picked up and a relatively small amount of growth is observed. A mass transfer model adequately describes solvent removal, and an empirical model is developed to describe the growth behavior in terms of measured process variables. The image system is applied to dried molding powders. The PSD measurement results of the PBX 9501 library lots, historic samples set aside as PBX 9501 lots were accepted from the manufacturer, are also discussed and analyzed. A correlation analysis was conducted to find relationships between the measured PSD and other properties such as bulk density and pressed densities. While no significant correlation was found between the measured PSD and averaged bulk densities for the library lots, significant correlations are found between the measured PSD and pressed density. The final part of the study was to scale-up the PSD measurement capability. Since the large-scale processes are not yet operational, this work makes recommendations for future consideration. Also, some additional small-scale experiments are recommended as well as improvements to the smallscale experimental apparatus.

Pressed plastic-bonded explosives, PBXs, are commonly used by defense and private industry. PBX 9501 is composed of HMX crystals held together with a plastic binder 'softened' with plasticizers. The detonation behavior of any explosive is very dependent upon its density, with the desire to have a uniform, high density throughout the explosive component. A parametric study has been performed pressing PBX 9501 hydrostatically and uniaxially. The effects of several pressing parameters on the bulk density and density profile, as well as mechanical properties, have been measured. The parameters investigated include pressure, temperature, number of cycles, dwell time, rest time, sack thickness, and particle distribution and size. Density distributions within the pressed explosives were also compared.

We have implemented the burn model in LS-DYNA. At present, the damage (porosity and specific surface area) is specified as initial conditions. However, history variables that are used by the strength model are reserved as placeholders for the next major revision, which will be a completely interactive model. We have implemented an improved strength model for explosives based on a model for concrete. The model exhibits peak strength and subsequent strain softening in uniaxial compression. The peak strength increases with increasing strain rate and/or reduced ambient temperature. Under triaxial compression compression, the strength continues to increase (or at least not decrease) with increasing strain. This behaviour is common to both concrete and polymer-bonded explosives (PBX) because the microstructure of these composites is similar. Both have aggregate material with a broad particle size distribution, although the length scale for concrete aggregate is two orders of magnitude larger than for PBX. The (cement or polymer) binder adheres to the aggregate, and is both pressure and rate sensitive. There is a larger bind binder content in concrete, compared to the explosive, and the aggregates have different hardness. As a result we expect the parameter values to differ, but the functional forms to be applicable to both. The models have been fit to data from tests on an AWE explosive that is HMX based. The decision to implement the models in LS-DYNA was based on three factors: LS-DYNA is used routinely by the AWE engineering analysis group and has a broad base of experienced users; models implemented in LS-DYNA can be transferred easily to LLNL's ALE 3D using a material model wrapper developed by Rich Becker; and LS-DYNA could accommodate the model requirements for a significant number of additional history variables without the significant time delay associated with code modification.

Two applications of thermal expansion measurements on plastic-bonded explosive (PBX) composites are described. In the first dilatometer application, thermal expansion properties of HMX-based PBX 9501 are measured over a broad thermal range that includes glass and domain-restructuring transitions in the polymeric binder. Results are consistent with other thermal measurements and analyses performed on the composite, as well as on the binder itself. The second application used the dilatometer to distinguish the reversible and irreversible components of thermal expansion in PBX 9502, a TATB-based explosive. Irreversible expansion of the composite is believed to derive from the highly-anisotropic coefficient of thermal expansion (CTE) values measured on single T A TB crystals, although the mechanism is not well understood. Effects of specimen density, thermal ramp rate, and thermal range variation (warm first or cold first) were explored, and the results are presented and discussed. Dilatometer measurements are ongoing towards gaining insight into the mechanism(s) responsible for PBX 9502 irreversible thermal expansion.

High fidelity measurements of time-dependent strain in the plastic-bonded explosives LX-17-1 and PBX 9502 have been performed under constant, uni-axial, compressive load using a custom designed apparatus. The apparatus uses a combination of extensometers and linear variable differential transformers coupled with a data acquisition system, thermal controls, and gravitational loading. The materials being tested consist of a crystalline explosive material mixed with a polymeric binder. The behavior of each material is related to the type of explosive and to the percentage and type of binder. For any given plastic-bonded explosive, the creep behavior is also dependent on the stress level and test temperature. Experiments were conducted using a 3 x 3 stress-temperature matrix with a temperature range of 24 C to 70 C and with stresses ranging from 250-psi to 780-psi. Analysis of the data has shown that logarithmic curve fits provide an accurate means of quantification and facilitate a long-term predictive capability. This paper will discuss the design of the apparatus, experimental results, and analyses.