Modelling and optimization of melt cast explosives fabrication process

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Melt-cast explosives charges are used not only in military systems, but also in civilian blasting operations where they act as "booster" to sustain the detonation of gel explosives formulations. These explosives are essentially a dispersion of solid crystals in a fusible matrix such as TNT. As for any explosives devices, the sizes and shapes of the charges are important to their performance. They are prepared by first mixing the solid ingredients in the hot melt explosive and then cast in a mold by gravity. Once filled, the mold is cooled to allow the fusible matrix to set. The rate of cooling process is critical to the quality of the final product. Improper temperature conditions will lead to cracks and trapped void in the part. This project is aimed at modelling the casting and cooling process of generic explosives parts as a means of improving their fabrication. It also has for objectives to facilitate the development of new formulations by studying how variables such as melt rheology and thermal properties affect the casting and cooling process. Therefore, whenever new ingredients will be used, it would be easier to adapt to these changes. The developed models will also be employed to increase safety when new formulations will be mixed for the first times.