Simulation of blast propagation and structural effects of accidental hydrogen-air-mixture explosion in a two-stage light-gas gun laboratory for hypervelocity impact experiments

Two-stage light-gas guns allow to accelerate projectiles up to velocities of several kilometers per second to conduct impact experiments. The projectile acceleration is obtained through a mechanism that relies on the expansion of a light gas, such as helium or hydrogen. Hydrogen allows to employ higher projectile velocities and masses than helium, together with lower wear of the launch tube. However, its use requires a thorough assessment of potential risks of explosion. In this work, we present a combined blast and structural numerical analysis to evaluate the effects of hydrogen deflagration as a consequence of accidental leakage scenarios during the operation of a two-stage light-gas gun. As a test case, we study the Large Gun operated at Fraunhofer EMI in Freiburg, Germany. The possible failure of non-structural elements, such as doors and windows, and the subsequent blast propagation into areas adjacent to the room hosting the facility are also accounted for. The simulation procedure presented in this work is scalable to similar and larger facilities for impact research as well as to other contexts involving analogous risks of gas explosions. •Accidental deflagration scenarios resulting from the hydrogen operation of a two-stage light-gas gun facility are studied.•A numerical procedure combining CFD and explicit structural dynamics simulations is described.•Exemplary results of blast effects and induced structural behavior are presented.•The use of results for assessment of safety levels and possible prevention countermeasures is discussed.