Propellant Burning Rate Research Articles

Theory-driven design of graphene-nickel gallate nanocomplex as functional catalyst for composite modified double base propellant

New graphene-nickel gallate nanocomplex (G-M-Ni) was designed, synthesized and characterized to deal with the requirement of functional combustion catalyst based on investigations of combustion mechanisms of propellant, structural analysis of catalyst and simulation results of quantum mechanics. The positive effect of G-M-Ni is not only reflected in the significantly increased burning rate, but also reflected in the reduction of friction sensitivity of composite modified double base (CMDB) propellant. The G-M-Ni nanocomplex exhibited significantly enhanced catalytic performances, and the burning rate of propellant at 20 MPa enhanced from 23.15 to 29.07 mm·s−1. Besides, the friction sensitivity of propellant reduced from 64 % to 36 % after addition of 0.5% G-M-Ni. The positive effect of G-M-Ni on CMDB propellant combustion is mainly attributed to its promotion impact on nitroglycerin (NG) pyrolysis, which significantly increased the differential charge density and decreased the decomposition activation energy (from 1.89 eV to 1.38 eV). The gas products produced by the rapid pyrolysis of NG are conducive to the heat feedback between the gas phase and the combustion surface, which makes the propellant have higher burning rate, bright flame, thin dark zone and flocculated quenching surface morphology. The findings in this study confirm the potential of G-M-Ni as a functional combustion catalyst for CMDB propellants, which has guiding significance and inspiration for the development of new combustion catalysts from the view of molecular-level insights. Novelty and significance statementRecently, graphene based functional combustion catalysts have attracted much attention in the field of solid propellants due to their excellent catalytic combustion performance, reduced sensitivity, and improved mechanical properties. Herein, novel graphene-nickel gallate nanocomplex (G-M-Ni) were designed, synthesized and characterized to deal with the to deal with the requirement of functional combustion catalyst based on investigations of combustion mechanisms of CMDB propellant, structural analysis of new material and simulation results of quantum mechanics. By taking graphene as the benchmark, the G-M-Ni nanocomplex exhibited significantly enhanced catalytic performances, and excellent effect on the reduction of friction sensitivity. The relationship between molecular structure of G-M-Ni and combustion characteristics of CMDB propellant were disclosed. The theory-driven design mode of this work may provide new pathways to tune combustion behaviors of CMDB propellants from the view of molecular-level insights.

Exploration of TKX-50-M (M=Pb, Bi and Cu) as insensitive high-energy combustion catalysts of HMX-CMDB propellant

In order to deal with the long-standing contradiction between safety and performance for propellent combustion catalyst, the TKX-50-M (M=Pb, Bi and Cu) were designed, synthesized and characterized. The density, thermal decomposition, mechanical sensitivity and energy performance of the prepared TKX-50-M were studied systemically. By taking NTO-Pb as the benchmark, the TKX-50-M exhibited much better energetic and safety properties. Besides, the combination of TKX-50-Pb, TKX-50-Cu and carbon black is conductive to the combustion of HMX-CMDB propellant. The burning rate of HMX-CMDB propellant increases from 16.80 to 21.28 mm s−1 at 20 MPa, and the pressure index reduces from 0.87 to 0.39 in the pressure range of 10–20 MPa. The catalytic mechanism of TKX-50-M were explored according to the results of combustion wave structure, flame image and characteristics of burning out surface. The catalytic effect of TKX-50-Pb is mainly reflected in the gas phase region, and the introduction of TKX-50-Cu and carbon black shows a significant synergistic catalytic effect. The results of this study not only help to explore insensitive high-energy combustion catalyst, but also helps to improve the combustion, energy and safety performance of CMDB propellants.

Control of burning rate pressure sensitivity for solid propellants by changing the interfacial contact of Al/HMX/AP with precisely located graphene-based energetic catalysts

The control of burning rate pressure sensitivity is essential for stable and reliable combustion of solid propellants. It has been proved that the combustion behavior of propellants can be effectively tuned by interfacial control of Al/oxidizers. In this work, core-shell Al-based composites, using oxidizers such as ammonium perchlorate (AP) and cyclotetramethylene tetranitramine (HMX) as the shell layer, have been prepared with a well-controlled location of graphene-based carbohydrazide complexes (GO-CHZ-M, M = Co2+ or Ni2+) as the catalysts. The catalysts can be located inside HMX or embedded on the surface of AP particles. The decomposition of AP and HMX could be greatly promoted with a trace amount of catalyst. Under the synergistic effects of Al/oxidizer interfacial control and GO-CHZ-M, the ignition delay time is shortened by >48 % with increased in flame radiation. More importantly, the burning rate (r) and pressure exponent (n) of the solid propellants are effectively regulated in a wide range. In particular, the use of Al@HMX/Co results in a lowered n of 0.29 within 1∼20 MPa compared to 0.79 for the blank reference sample. The agglomeration of Al particles during combustion was also inhibited due to the micro-explosion effect of Al@HMX composites. Novelty and Significance statementThe innovative approaches of integrating Al/HMX/AP composites and precise catalysis of graphene-based energetic catalysts in solid propellants have successfully achieved, regarding the modulation of the burning rates and pressure sensitivity. Moreover, the effect of catalyst location on the ignition delay and burning rates has also been studied thoroughly and clarified. This paper provides new insight into the regulation of combustion performance of solid propellants, with improved reaction efficiency and maintained energy density.

Analysis of thermal stability for slow burning propellant based on isothermal testing: Self‐accelerating decomposition temperature (SADT) calculation and validation

AbstractBurning rate suppressants (BRSs) refer to a series of additives that reduce the burning rate of propellants, crucial for achieving sustained and stable thrust. This research focuses on assessing the impact of ammonium sulfate and ammonium oxalate on thermal stability and their potential as BRSs. Due to the stronger inhibitory effect of ammonium sulfate on the AP proton transfer process, the activation energy of propellant's first decomposition can be increased from 94.71 kJ mol−1 to 129.69 kJ mol−1 at a 3 % addition level. Based on Semenov model, the self‐accelerated decomposition temperatures (TSADT) were calculated and validated through 7‐day isothermal test. Introducing ammonium sulfate and ammonium oxalate raised the TSADT from 197.31 °C to 220.90 °C and 215.06 °C, respectively, deviating less than 4 % from experimental results. Among the propellants tested, those with ammonium sulfate showed prolonged response delay times (44.43–33.60 h), lower superheating temperatures (222.8–445.5 °C), and reduced mass loss rates (33.0–71.4 %) after 7 days of isothermal storage at 220–240 °C. The consistency between thermal analysis and isothermal test underscores the significant impact of activation energy on thermal stability.

Effects of Wire-Wrapping Patterns and Low Temperature on Combustion of Propellant Embedded with Metal Wire

Incorporating silver wires into propellant has emerged as a highly effective strategy for enhancing propellant burning rates, a technique extensively deployed in the construction of numerous fielded sounding rockets and tactical missiles. Our research, employing a multi-faceted approach encompassing thermogravimetric-differential scanning calorimetry measurements (TG-DSC), combustion diagnoses, burning rate tests, and meticulous collection of condensed combustion products, sought to elucidate how variations in silver wire quantity and winding configuration impact the combustion properties of propellants. Our findings underscore the remarkable efficacy of double tightly twisted silver wire in significantly boosting propellant burning rates under ambient conditions. Moreover, at lower temperatures, the reduced gap between the propellant and silver wire further magnifies the influence of silver wire on burning rates. However, it is noteworthy that the relationship between burning speed and combustion efficiency is not deterministic. While a smaller cone angle of the burning surface contributes to heightened burning rates, it concurrently exacerbates the polymerization effect of vapor phase aluminum particles, consequently diminishing propellant combustion efficiency. Conversely, propellants configured with sparsely twinned silver wires exhibit notable enhancements in combustion efficiency, despite a less pronounced impact on the burning rate attributed to the larger cone angle of the burning surface. Remarkably, these trends persist at lower temperatures. Based on the principle of heat transfer balance, a theoretical model for the combustion of propellants with wire inserts is developed. The reliability of this theoretical model is validated through a comparison of calculated values with experimental data. Our research outcomes carry significant implications for guiding the application and advancement of the silver wire method in solid propellants for solid rocket motors, offering valuable insights to inform future research and development endeavors in this domain.

Theory-driven design of graphene schiff base iron nanocomplex as catalyst for composite propellant

New graphene Schiff base iron nanocomplexes (S-792-Fe, S-550-Fe, and S-590-Fe) were designed and fabricated based on investigations of reactions mechanisms of AP pyrolysis, structural analysis of new materials and simulation results of quantum mechanics to deal with the long-standing contradiction between safety and performance for composite propellent combustion catalyst. By taking traditional catalyst Catocene as the benchmark, the S-550-Fe nanocomplexes exhibited competitive catalytic performances, much better anti-migration properties and significantly reduced impact and electrostatic sensitivities. After adding S-550-Fe, the burning rate of propellant enhanced from 13.87 to 19.77 mm s−1 at 15 MPa, and the impact and electrostatic sensitivities are improved to 50.2 cm and 172.12 mJ, respectively. The excellent catalytic performance of S-550-Fe is closely related to its molecular structure, which is manifested by an increase in charge density and a decrease in NH3 oxidation energy barriers. The promotion effects of S-550-Fe on desorption and oxidation of NH3 from the surface of AP is conducive to the rapid and complete pyrolysis of AP, which is reflected in the improvement of combustion rate and temperature gradient. The theory-driven design mode of this work may provide new pathways to tune combustion behaviors of composite propellants from the view of molecular-level insights.

Evaluation of solid propellant burning rate by using strand burner and static firing tests

Abstract The main objective of this paper is to compare the different methods used to measure the burning rate of hydroxyl-terminated polybutadiene (HTPB) propellant. The burning rate measurement is carried out under varying crosslinking density, which is determined by the curing ratio, i.e., the equivalent ratio of diisocyanate to total hydroxyl (NCO/OH) ratio. Four batches with different curing ratios were produced using fixed production processes. To measure the burning rate, cured solid propellant strands were tested using the acoustic wave emission method at different pressures ranging from 4 to 10 MPa and also by using static firing test of subscale motors. The study showed that there was little difference between the results obtained from the acoustic wave emission method and subscale motors.

Closed vessel burning rate measurements of composite propellants using microwave interferometry

AbstractBurning rate as a function of pressure is one of the primary evaluation metrics of solid propellants. Most solid propellant burning rate measurements are made at a nearly constant pressure using a variety of measurement approaches. This type of burning rate data is highly discretized and requires many tests to accurately determine the burning rate response to pressure. It would be more efficient to measure burning rate dynamically as pressures are varied. Techniques used to make transient burning rate measurements are reviewed briefly and initial results using a microwave interferometry (MI) technique are presented. The MI method used in tandem with a closed bomb enables nearly continuous measurement of burning rates for self‐pressurizing burns, capturing burning rate data over a wide range of pressures. This approach is especially useful for characterization of propellants with complex burning behaviors (e. g., slope breaks or mesa burning). The burning rates of three research propellants were characterized over a pressure range of 0.101–24.14 MPa (14–3500 psi). One research propellant exhibited a slope break at a pressure of 6.63 MPa (960 psi). Using MI in a closed pressure vessel, 14 propellant strand burns resulted in a nearly continuous burning rate curve over a pressure range of 0.41–24.13 MPa (60–3500 psi) that reasonably matched conventional burning rate measurements. The development of this technique provides an opportunity to quickly characterize the burning rate curve of solid propellants with greater fidelity and efficiency than traditional quasi‐static pressure testing techniques.

A numerical determination of complex solid gun propellant burn rates through closed bomb simulation

AbstractClosed bomb testing is a prominent means of characterizing the combustion behavior of solid gun propellants. This sub‐scale test allows the propellant to burn in a constant volume environment, where the resulting pressure‐time trace can be collected via a pressure transducer. Historically, numerical procedures have been developed to determine the burn rates of the gun propellants from these pressure‐time traces; however, no standardized procedure exists to determine the burn rates of grains with variable surface thermochemistry and ignition criteria. To address this capability gap, a non‐linearly constrained, multivariate optimization algorithm has been developed to decouple propellant grain surfaces and determine surface‐specific burn rates [1]. In this work, the optimization algorithm as well as the legacy Excel‐based Closed Bomb (XLCB) program [2] were used to determine the burn rates of homogeneous, deterred, and layered propellants from experimental data. Closed bomb simulations using these burn rates were then conducted with the two‐phase, multidimensional, interior ballistics solver, iBallistix [3]. The maximum mean error between the simulated and experimental pressure‐time curves was 6.8 % for the optimization algorithm and 23.8 % for XLCB, showing a marked improvement with our new approach. Furthermore, the approach discussed herein improves burn rate predictions of complex solid gun propellants when compared with legacy closed bomb data reduction analysis programs.

On‐demand microwave growth of porosity within a granular composite energetic material: Void formation via a dielectric loss phase change binder additive for propellant burning rate control

AbstractThis study demonstrates, for the first time ever, the ability to grow, in an on‐command fashion, porosity within a granular composite energetic material to effect a change in energy output rate. Specifically, the study investigates the change in burning rates of ammonium perchlorate composite propellants as a result of porosity created in situ via microwave field‐driven volatilization of the low boiling point binder additive, ethylene glycol. Theoretical mass densities were measured before and after microwave irradiation finding that the maximum observed %TMD change for tested propellants is 6 %. Propellants were burned at 1.72 MPa to 6.89 MPa pressures, finding that for all propellants, microwave irradiation produced a change in ballistic characteristics. Most propellant formulations demonstrate acceptable burning rate parameters for use within rocket motors; some exhibited a large change in their pressure exponent as well as slope breaks attributed to the onset of convective burning, while microwave irradiation produced no change in burning rate or density in reference propellants without the additive. Microwave heating simulation results are presented to gain insight into the thermal environment of the propellant during microwave irradiation. These results provide valuable insight into propellant formulations that can have their burning rates (and thus the thrust profile for motor grains) altered after casting via microwave irradiation.

Solid propellant burn rate characterization: Effect of copper chromite blend with oxidiser and its storage

This work details the study conducted on composite solid propellants with activated copper chromite (ACR) as burn catalyst for its burn rate change with time due to the interaction of ammonium perchlorate (AP) with ACR. One of the hypotheses cited for burn rate reduction is the conversion of chromite in ACR to chromate by an electrolytic reaction with moisture in the presence of ammonium perchlorate. This hypothesis was studied by a design of experiments which includes blending ammonium perchlorate and ACR, Aluminum and ACR, stand alone ACR in raw material stage and the blends storage with time. The effect of moisture in AP is addressed by comparing undried and dried AP in the blends. The blended raw materials were characterized by Thermo-gravimetric analysis, Particle Size Distribution, surface area measurement, Scanning Electron Microscopy and chromium estimation. Results show that the conversion of chromium from chromite to chromate is very minimum in the presence of AP. Propellant samples are prepared with these blends at different time intervals to understand viscosity, mechanical properties and burn rate behavior with raw material storage. Experimental results show burn rate shows an opposite trend of increase with blend storage of 6 months. A plausible explanation for this observation is presented in the paper correlating the experimental conditions.

Titanium a novel catalyst and high energy dense material: an opportunity for composite propellants with enhanced performance

ABSTRACT Whereas aluminum with combustion enthalpy of 32 KJ/g is the universal reactive metal particles, its passive protective oxide layer could encounter its efficient combustion. While titanium can offer low combustion enthalpy (20 KJ/g), it does not expose passive oxide layer. The impact of both reactive particles on ammonium perchlorate (AP) decomposition enthalpy was investigated via DSC. Aluminum and titanium particles secured an increase in AP decomposition enthalpy by 46.9%, and 80.7% respectively. This significant impact of titanium particles was ascribed to full exploitation of metal energy content. The impact of titanium particles on AP decomposition kinetics was assessed via Kissinger, KAS, and FWO models using TGA. Whereas virgin AP demonstrated average apparent activation energy of 155 KJ/mol, Ti/AP demonstrated average apparent activation energy of 141.2 KJ/mol. Solid rocket propellant formulations based on 17 wt % metal (Al or Ti) were developed via mixing and vacuum casting. Ballistic performance was investigated using small-scale ballistic evaluation rocket motor. Ti-based formulation offered an increase in propellant burning rate, average operating pressure, average thrust by 18.2%, 26.5%, and 19.7% respectively. It was concluded that titanium particles have a dual effect as efficient high energy dense material and as a catalyst.

Tuning combustion and energy in hydroxylammonium nitrate (HAN)-based electrically controlled solid propellant

Solid propellants have been widely applied due to its high energy, rapid reaction, easy storage and convenient equipment. However, the further development of solid propellants has been hindered by the challenges associated with controlling their combustion process. In this research, we presented an electrically controlled solid propellant (ECSP), and its burning rate could be continuously adjusted with voltage. We investigated thermal decomposition behavior and gaseous products of ECSP using thermogravimetry–differential scanning calorimetry-mass spectrometry (TG-DSC-MS). The solid products were analyzed through energy dispersive spectroscopy (EDS) and X-ray photoelectron spectroscopy (XPS). Based on the thermal decomposition behavior, gaseous products, and solid products, it was found that the thermal decomposition process could be divided into two stages: decomposition of ammonium nitrate (AN) and interactions between hydroxylamine nitrate (HAN) and other substances. The electrochemical impedance spectroscopy (EIS) experiments revealed that the electrical conductivity of ECSP increased with the pressure. Significantly, the peak combustion pressure of propellant increased by the rise of voltage from 3.17 MPa (150 V) to 5 MPa (250 V) in closed bomb. In addition, electricity reinforced the burning rate and powder force of propellant. Additionally, the electricity simultaneously affects electric and thermal decomposition processes. Electricity is used to control the burning rate and the total energy produced by propellant combustion. The characteristics of controllable energy has the potential to achieve controllable range of weapons, providing a new direction for development of smart weapons.

Chemical behavior research of high-energy aerospace propellant with a mesoscale heterogeneous packing model

The NEPE propellant has a wide range of applications in the aerospace field, playing a crucial role in enhancing the performance and efficiency of propulsion systems. In this study, we have developed an elaborate physical–chemical model to simulate the transient reaction characteristics of NEPE propellants. Our approach entails a sequential algorithm to explore the microstructure of NEPE propellants, incorporating a novel semi-global kinetic reaction mechanism designed to accurately represent real-world scenarios during propellant combustion. The interplay between the condensed phase and gas phase is handled through the use of the source term method. A comprehensive examination is carried out to ensure the statistical convergence of the propellant particle distribution. Moreover, we have compared the simulated burning rate of NEPE propellant under different formulations and operating pressures (ranging from 0.5 to 2.5 MPa) with experimental cases. The predictions demonstrate excellent agreement within a 10 % margin of the experimental data, highlighting the precision with which our proposed model depicts propellant combustion. Furthermore, we have conducted simulations of the combustion of specific NEPE disk packs composed of 19.63 % 100 µm AP, 35.3 % 60 µm HMX, 8.83 % 50 µm HMX, and 36.25 % NG/BTTN binder. Our findings reveal that the variation of statistical burning rates can be described by the equation rb=3.93P0.453, Additionally, the adiabatic flame temperature of the disk packs, under various pressures, typically falls within the range of 3200–3700 K. To gain a deeper understanding of the impact of different components within the propellant on combustion, we have carried out burning tests on a series of NEPE disk packs with varying formulations, accompanied by particle-scale combustion analysis. Our observations indicate that substituting 1 % HMX particles for AP particles leads to a significant enhancement in the propellant’s burning rate, approximately 0.02 mm/s. This phenomenon confirms that HMX particles act as a potent explosive source, thereby contributing to an increased flame standoff distance. Consequently, a jet-like diffusion flame with a length scale of several microns commonly appears above the AP-binder-HMX unit.

Methodology for Studying Combustion of Solid Rocket Propellants using Artificial Neural Networks

The combustion properties of energetic materials have been extensively studied in the scientific literature. With the rapid advancement of data science and artificial intelligence techniques, predicting the performance of solid rocket propellants (SRPs) has become a key focus for researchers globally. Understanding and forecasting the characteristics of SRPs are crucial for analyzing and modeling combustion mechanisms, leading to the development of cutting-edge energetic materials. This study presents a methodology utilizing artificial neural networks (ANN) to create multifactor computational models (MCM) for predicting the burning rate of solid propellants. These models, based on existing burning rate data, can solve direct and inverse tasks, as well as conduct virtual experiments. The objective functions of the models focus on burning rate (direct tasks) and pressure (inverse tasks). This research lays the foundation for developing generalized combustion models to forecast the effects of various catalysts on a range of SRPs. Furthermore, this work represents a new direction in combustion science, contributing to the creation of a High-Energetic Materials Genome that accelerates the development of advanced propellants.

FTIR Characterization and Thermal Decomposition Kinetics of AN/AP-Based Composite Solid Propellants

ABSTRACT Solid Rockets are one of the most efficient and reliable rockets, but production of chlorine gases in the exhausts of these rockets is a major drawback. The toxic exhaust is due to the presence of ammonium perchlorate (AP) as the oxidizer. Thus, the solution to decrease this exhaust is the use of green oxidizers such as ammonium nitrate (AN), but it suffers from the drawback of low energetics and hygroscopicity, phase transitions at room temperatures, and incomplete combustion in pure form. The present work emphasizes the phase stabilization of AN in the presence of AP and cobalt nitrate hexahydrate (CNH) catalyst. FTIR study helps to identify present functional groups in the propellant samples. The thermal decomposition of AN/AP-based propellant samples was investigated with an STA Instrument under a nitrogen atmosphere with different heating rates. The kinetic studies reveal the steps of reactions and activation energy of propellant samples which were observed to change with the addition of AN and CNH. The overall studies confirm that AP and catalyst CNH help in the phase stabilization of AN in propellant samples and enhance the combustion reactions at lower temperatures. The burn rate and flame temperature of the AN-AP propellant sample are found to increase with the addition of a catalyst. The catalyst positively effects the energy barrier or activation energy, burn rate, and flame temperature of AN-AP propellant, thus confirming that the catalyst helps in the combustion process.

Ferrocene-fullerene dyad as a novel burn rate modifier for propellants

The burn rate of composite rocket propellants serves as a critical ballistic parameter in the construction of a rocket engine. Due to their large surface areas, carbon-based materials such as carbon nanotubes, graphene, and fullerene have demonstrated promising results as burn rate modifiers (BRMs) for propellants. Unlike their inorganic counterparts, these materials, being combustible, contribute to energy output besides enhancing the burn rate. This study reported a ferrocene-fullerene dyad as a BRM prepared through the thermal decomposition of ammonium perchlorate (AP) in composite solid propellants. By incorporating 0.6 wt% of the dyad, the burn rate of the prepared propellants increased by 70%, accompanied by a rise in their calorific value.

Исследование газодинамики горения смесевого твердого топлива при колебаниях давления

The non-stationary burning rate of a solid rocket propellant under harmonic variations in pressure over the combustion surface is studied. The physical and mathematical model is based on the equations of heat transfer and oxidizer decomposition in the solid phase, and on the flow model for the reacting products of solid propellant gasification. Calculations are carried out for the unsteady burning rate of mixed solid propellants with harmonic pressure variations over the combustion surface. The dependence of the amplitude of the burning rate fluctuations on the frequency of the pressure variations are obtained. The amplitude of the burning rate varies non-monotonically with frequency. As the frequency increases, the amplitude first increases and then decreases. At a frequency of pressure variation with a semi-period greater than or equal to the characteristic time of relaxation for heat transfer in solid propellants, the instantaneous burning rate at the lowest point of the pressure curve is lower than the equilibrium value and is higher at the highest point. At high frequencies, the burning rate exceeds the corresponding equilibrium value at minimum pressure and is lower than the equilibrium value at maximum pressure.

ELECTROCHEMICAL BURN RATE ACCELERATION

An electrochemical mechanism of accelerating the burn rate of pyrotechnic compositions and composite propellants is presented. Magnesium-Teflon-graphite fluoride-graphite (MTGFG) compositions were used as the model system to demonstrate the effect. Electric currents are generated in situ by electrochemical cell reactions in the composition itself by introducing materials with differing electrochemical potentials and an electrolyte into the composition. Electric currents flow through the combusting surface, where materials melt and allow ion transport. The electrochemical cell is shorted at the burning surface providing more heat feedback than the back radiation from the flame alone accelerating the combustion considerably. No external power source nor auxiliary electrodes are required to increase the burn rate by electric currents like with methods hitherto known. Up to a 2.5-fold increase in the burn rate of baseline composition was achieved by using graphite as the cathode material, the magnesium powder in the composition as anode, and graphite fluoride (GF) as depolarizer and oxidizer in the cell reactions. Various electrolytes were investigated keeping the base composition otherwise unchanged.

Mussel-inspired PTW@PDA composites for developing high-energy gun propellants with reduced erosion and enhanced mechanical strength

The severe erosion and inadequate mechanical strength are prominent challenges for high-energy gun propellants. To address it, novel PTW@PDA composites was prepared by polydopamine(PDA)-modifying onto potassium titanate whisker(PTW, K2Ti6O13), and after was incorporated into gun propellant as erosion-reducing and mechanical-reinforcing fillers. The interfacial characterizations results indicated that as-prepared PTW@PDA composites exhibits an enhanced surface compatible with propellant matrix, thereby facilitating their dispersion into propellants more effectively than raw PTW materials. Compared to original propellants, PTW@PDA-modified propellants exhibited significant less erosion, with a Ti–K-based protective coating being detected on the eroded steel. And 0.5 wt% and 1.0 wt% addition of PTW@PDA significantly improved impact, compressive and tensile strength of propellants. Despite the inevitably reduction in relative force, PTW@PDA slightly increase propellant burning rate while exerting little adverse impact on propellant dynamic activity. This strategy can provide a promising alternative to develop high-energy gun propellant with less erosion and more mechanical strength.