Enhancement of the energetic performance of solid fuels with metal-fluoropolymer additives

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Aluminum (Al) holds a pivotal role in augmenting the energetic potential of solid fuel formulations. Its incorporation can notably amplify the energy yield upon combustion. Nevertheless, challenges such as ignition delay and incomplete combustion have hindered its optimal utilization. In the context of hybrid rocket propulsion, where reignition and high regression rates are sought, a promising solution lies in harnessing the potential of metal-fluoropolymer combinations. This paper explores the influence of polytetrafluoroethylene (PTFE) and Viton fluoropolymer additives on the combustion and regression rates of hydroxyl‑terminated polybutadiene (HTPB)-based solid fuels loaded with nano-aluminum (nAl). To comprehensively address these objectives, binary composites of nAl-PTFE and nAl-Viton were prepared using high-energy ball-milling, and the resulting mixtures were incorporated into hydroxyl‑terminated polybutadiene (HTPB)-based fuel through a vacuum-casting technique. The ignition and combustion characteristics of the solid fuels, as well as the post-combustion products, were examined using an opposed flow burner setup to gain insights into their oxidation and combustion mechanisms. The findings demonstrate that the inclusion of PTFE and Viton in nAl has a positive impact on the ignition delay time, combustion behavior, and regression rates of the solid fuels. The HTPB-nAl-PTFE(S3) sample exhibited the shortest ignition delay time of 108 ms, outperforming the other tested samples (S1: 227 ms, S2: 182 ms, S4: 122 ms). Furthermore, the addition of nAl to pure HTPB resulted in an average regression rate of 0.3–0.6 mm/s for HTPB-nAl (S2), representing a two fold improvement compared to pure HTPB-based samples. Compared to the baseline HTPB fuel, HTPB-nAl-PTFE(S3) demonstrated a significant increase in regression rate by approximately 178%, while HTPB-nAl-Viton(S4) exhibited an increased regression rate of 122%. These results highlight the positive influence of fluoropolymers on combustion behavior, ultimately enhancing the overall performance of the fuel. Additionally, the study observed gas-phase reactions during the combustion process, including the reaction between nano-aluminum (nAl) and fluoride, the intermediate product of Al oxidation, and the decomposition products of fluoride. These reactions resulted in the faster fracture of the alumina (Al2O3) shell, leading to improved heat release and regression rate performance.