When describing the relation between the flow stress and plastic strain of a material under a wide range of strain rates and temperatures, the original Johnson–Cook model generally requires a complicated modification, resulting in a loss of simplicity and clear physical interpretation. In this paper, without modification, the original Johnson–Cook model was calibrated separately for the static and dynamic compression of a DNAN-based melt-cast explosive. The stress–strain curves for static and dynamic compression of this explosive were experimentally measured with a universal testing machine and a split-Hopkinson pressure bar, respectively. Based on the stress–strain curves, the flow stress vs. plastic strain data were extracted and used to calibrate the Johnson–Cook model. The calibration process is described. The parameters for the strain term, strain rate term, and temperature term were fitted sequentially. One set of model parameters was not able to fully describe the relationship between flow stress and plastic strain for both the static and dynamic compression of the DNAN-based melt-cast explosive. Two sets of model parameters were separately calibrated and compared for the static and dynamic compression of this explosive. The effects of the adiabatic temperature rise and the definition of the yield point on this calibration were also investigated.

As a matrix for melt-cast explosives, 3,4-dinitropyrazole (DNP) is a promising alternative to 2,4,6-trinitrotoluene (TNT). However, the viscosity of molten DNP is considerably greater compared with that of TNT, thus, requiring the viscosity of DNP-based melt-cast explosive suspensions to be minimized. In this paper, the apparent viscosity of a DNP/HMX (cyclotetramethylenetetranitramine) melt-cast explosive suspension is measured using a Haake Mars III rheometer. Both bimodal and trimodal particle-size distributions are used to minimize the viscosity of this explosive suspension. First, the optimal diameter ratio and mass ratio (two crucial process parameters) between coarse and fine particles are obtained from the bimodal particle-size distribution. Second, based on the optimal diameter ratio and mass ratio, trimodal particle-size distributions are used to further minimize the apparent viscosity of the DNP/HMX melt-cast explosive suspension. Finally, for either the bimodal or trimodal particle-size distribution, if the original data between the apparent viscosity and solid content are normalized, the resultant plot of the relative viscosity versus reduced solid content collapses to a single curve, and the effect of the shear rate on this curve is further investigated.

Thermal conductivity is one of the most important thermophysical properties of a melt-cast explosive. However, the temperature-dependent thermal conductivity of such explosives cannot be easily measured across the whole solidification process (including the liquid, semi-solid, and solid states). This study used an inverse analysis method to estimate the temperature-dependent thermal conductivity of a 2,4-dinitroanisole/cyclotetramethylenetetranitramine (DNAN/HMX) melt-cast explosive in a continuous way. The method that was used is described here in detail, and it is verified by comparing the estimated thermal conductivity with a prespecified value using simulated measurement temperatures, thereby demonstrating its effectiveness. Combining this method with experimentally measured temperatures, the temperature-dependent thermal conductivity of the DNAN/HMX melt-cast explosive was obtained. Some measured thermal conductivity values for this explosive in the solid state were used for further validation.