Manufacturing Commercial Explosive Simulants

XM Commercial Simulants mimic explosives commonly used in mining, quarrying and civil construction. There are simulants for Dynamite and for three generic emulsion/water gel-type explosives (Low, Medium and High Z explosives). These simulants are prepared in the large Cowles dissolver normally used for manufacturing paints. See Figure 4.

Water is first added to the mixing vessel, followed by solids with the appropriate density and atomic number. Small amounts of preservative and gelling agents are added to produce the final mixture with a consistency similar to toothpaste. Mixing is done at room temperature. These simulants are then extruded into sausages or bulk packaged in pails. Figure 5 shows both packaged XM commercial explosive simulants and artist's paints produced in this equipment.

Manufacturing Melt-Cast Explosive Simulants

XM produces three simulants for the high energy melt-cast explosives TNT, Tritonal and Comp B. These simulants are produced in the same mixing equipment as the commercial explosive simulants but at higher temperature (70C to 90C). A wax-like material is first melted and solids with the desired density and atomic number are added at temperature with mixing until uniform. Figure 6 shows the molten TNT simulant being mixed.

The molten simulant is solidified into sheets, ground into small flakes and packaged in pails. The flake material can also be melted and cast into molds to produce precise shapes. See Figure 7.

Manufacturing Gun Powder Simulants

XM makes simulants for both Black and Smokeless powder. Solids with the appropriate densities and atomic numbers are mixed in the large powder blender shown in Figure 8. A simulant for the granular explosive ANFO (ammonium nitrate/fuel oil) is also made in this blender.

Conclusion

Large scale production equipment used for making artist’s clays and paints has proven to be ideally suited for preparing a suite of explosive X-ray simulants. Over five thousand pounds of these materials have been produced during the past few years. These X-ray simulants are now being used extensively in the testing of equipment and training of personnel at numerous airports.

X-ray simulants are packaged in three kits. One each high energy military explosives, gun powders, and blasting explosives. These three kits are depicted in Figure 9.

Fig. 4 (click to enlarge)

Fig. 5 (click to enlarge)

Fig. 6 (click to enlarge)

Fig. 7 (click to enlarge)

Manufacturing Commercial Explosive Simulants

XM Commercial Simulants mimic explosives commonly used in mining, quarrying and civil construction. There are simulants for Dynamite and for three generic emulsion/water gel-type explosives (Low, Medium and High Z explosives). These simulants are prepared in the large Cowles dissolver normally used for manufacturing paints. See Figure 4.

Water is first added to the mixing vessel, followed by solids with the appropriate density and atomic number. Small amounts of preservative and gelling agents are added to produce the final mixture with a consistency similar to toothpaste. Mixing is done at room temperature. These simulants are then extruded into sausages or bulk packaged in pails. Figure 5 shows both packaged XM commercial explosive simulants and artist's paints produced in this equipment.

Manufacturing Melt-Cast Explosive Simulants

XM produces three simulants for the high energy melt-cast explosives TNT, Tritonal and Comp B. These simulants are produced in the same mixing equipment as the commercial explosive simulants but at higher temperature (70C to 90C). A wax-like material is first melted and solids with the desired density and atomic number are added at temperature with mixing until uniform. Figure 6 shows the molten TNT simulant being mixed.

The molten simulant is solidified into sheets, ground into small flakes and packaged in pails. The flake material can also be melted and cast into molds to produce precise shapes. See Figure 7.

Manufacturing Gun Powder Simulants

XM makes simulants for both Black and Smokeless powder. Solids with the appropriate densities and atomic numbers are mixed in the large powder blender shown in Figure 8. A simulant for the granular explosive ANFO (ammonium nitrate/fuel oil) is also made in this blender.

Conclusion

Large scale production equipment used for making artist’s clays and paints has proven to be ideally suited for preparing a suite of explosive X-ray simulants. Over five thousand pounds of these materials have been produced during the past few years. These X-ray simulants are now being used extensively in the testing of equipment and training of personnel at numerous airports.

X-ray simulants are packaged in three kits. One each high energy military explosives, gun powders, and blasting explosives. These three kits are depicted in Figure 9.