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Day 1:

Intro/Motivation

Engin C. Sengezer

Department of Aerospace and Ocean Engineering, Virginia Tech, Blacksburg VA

Polymer Bonded Explosives

XTX 8004 (80 wt% PETN-20 wt% PDMS)

AOE 3054 Experimental Methods

Mock Energetic Composite

Fabrication Procedure

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Day 1:

Intro/Motivation ALUMINUM MOLDs

2

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Day 1:

Intro/Motivation STEP 1

3

Measure the total weight of PDMS part A and B required corresponding to “X” wt%

particulate (sugar) amount to fabricate tension, compression, compact tension and Charpy

mock energetic composites using the EXCEL sheet provided

Repeat step 1 for your two different particulate weight concentrations

PDMS wt% 20

Sugar wt% 80

PDMS weight [g] 29.42

Sugar weight [g] 117.7

Weight ratio [g] 4

PDMS volume [ml] 28.56

Sugar volume [ml] 74

Volume ratio 2.591

Sugar vol % 72.15

FIRST BATCH

PDMS wt% 80

Sugar wt% 20

PDMS weight [g] 120.6

Sugar weight [g] 30.16

Weight ratio 0.25

PDMS volume [ml] 117.1

Sugar volume [ml] 18.97

Volume ratio 0.162

Sugar vol % 13.94

SECOND BATCH

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Day 1:

Intro/Motivation STEP 2

4

Turn on the scale (0/I)

Change unit to “grams’’ (Unit button)

Place the filter flask on the scale

Tare (zero) the scale (→ 𝑇 button)

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Day 1:

Intro/Motivation STEP 3

5

Pour the required PDMS Part A into your first

filter flask as your FIRST BATCH

10 Part A vs 1 Part B by weight

PDMS part A

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Day 1:

Intro/Motivation STEP 4

6

PDMS Part B

Pour the required PDMS Part B into your first

filter flask to finalize your FIRST BATCH

Repeat 2-4 for your SECOND BATCH

10 Part A vs 1 Part B by weight

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Day 1:

Intro/Motivation STEP 5

7

FIRST BATCH SECOND BATCH

Place magnetic stirring

bars into your batches

Stir at a speed of 3 at

40 Celcius for 5 mins

Increase the speed to 4

after at 40 Celcius

Stir 5 more mins

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Day 1:

Intro/Motivation STEP 5 alternative

8

Normal beaker can be used instead of filter

flask.

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Day 1:

Intro/Motivation STEP 6

9

Degassing your PDMS mixture within filter flasks to get rid bubbles for 30 mins or less

This configuration attached to vacuum pump will be provided

TEAM A

TEAM B1st Batch 2nd Batch

1st Batch

2nd BatchDo not degas any polymer more than 100 ml using filter flask

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Day 1:

Intro/Motivation STEP 6 continues

10

𝑇0 𝑇1

𝑇2𝐀𝐟𝐭𝐞𝐫 𝟑𝟎 𝐦𝐢𝐧𝐬

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Day 1:

Intro/Motivation STEP 7

11

Take your filter flasks

1st Batch 2nd Batch

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Day 1:

Intro/Motivation STEP 7 Alternative

12

1st Batch

2nd Batch

Degassing can be done in this chamber.

Do not degas any polymer more

than 150 ml using 1000 ml beaker

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Day 1:

Intro/Motivation STEP 8

13

Following STEP 1, pour the required particulate (sugar ) into your beaker for 1st BATCH

Following STEP 1, pour the required particulate (sugar ) into your beaker for 2nd BATCH

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Day 1:

Intro/Motivation STEP 8 continues

14

PDMS

20 wt%

1st Batch2nd Batch

Particulate

80 wt% (sugar)

Particulate

20 wt% (sugar)PDMS

80 wt%

TEAM A

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Day 1:

Intro/Motivation STEP 9

15

Pour at most 2 table spoon of particulates (sugar

crystals) at a time into your corresponding

batches

Coat the particulates (sugar crystals) by stirring

with lab spoon slowly

Follow Step 5 for only 5 mins at a speed 3 at 40

Celcius for particulate wt% ≤ 40

80/20 wt%

Sugar-PDMS

20/80 wt%

Sugar-PDMS

TEAM A

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Day 1:

Intro/Motivation STEP 10

16

Spray mold release agent into your aluminum molds

This step will be done before each team arrives

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Day 1:

Intro/Motivation STEP 11

17

Cast particulate composite mixtures into aluminum molds and cure for 1 hour at 100 ℃

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Day 1:

Intro/Motivation STEP 12

18

90/10 wt% Sugar-PDMS

Kapton film is used to mask the molds for particulate weight concentration > 80 wt%

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Day 1:

Intro/Motivation STEP 12

19

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Day 1:

Intro/Motivation Compact Tension Sugar –PDMS Mock Energetics

20

0 wt% 10 wt% 20 wt%

30 wt% 40 wt%

50 wt% 60 wt% 70 wt%

80 wt% 90 wt%

0 wt% 10 wt% 20 wt% 30 wt% 40 wt%0 wt% 10 wt% 20 wt% 30 wt% 40 wt% 50 wt% 60 wt%

70 wt% 80 wt% 90 wt%

a) b)

c) d)

As-produced Compact Tension mock energetics: Particulate wt% is 0-90

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Day 1:

Intro/Motivation Dogbone Sugar –PDMS Mock Energetics

21

0 wt%

10 wt%

20 wt%

30 wt%

40 wt%

50 wt%

60 wt%

70 wt%

80 wt%

90 wt%

As-produced dogbone mock energetics: Particulate wt% is 0-90

a) b)

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Day 1:

Intro/Motivation Charpy Sugar –PDMS Mock Energetics

22

0 wt%

10 wt%

20 wt%

30 wt%

40 wt%

50 wt%

60 wt%

70 wt%

80 wt%

90 wt%

a) b)

As-produced Charpy mock energetics: Particulate wt% is 0-90

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Day 1:

Intro/Motivation Compression Sugar–PDMS Mock Energetics

23

0 wt% 10 wt% 20 wt% 30 wt% 40 wt%

50 wt% 60 wt% 70 wt% 80 wt% 90 wt%

As-produced compression mock energetics: Particulate wt% is 0-90