Propellant Formulations Research Articles

Effect of Dual Curing Agent (TDI:DDI) on the Mechanical Properties and Burning Rate of HTPB-Based Solid Propellant

ABSTRACT In this study, the effect of dual curing agent (toluene diisocyanate:dimeryl diisocyanate (TDI:DDI)) on the properties of hydroxyl-terminated polybutadiene (HTPB)-based solid propellant (such as mechanical strength, elongation percentage, elastic modulus, hardness, burning rate and pressure exponent (n)) has been investigated. Thus, five solid propellant formulations with different proportional amounts of TDI and DDI, with same loading rate and constant R value, were prepared, and the mechanical properties and burning rate of the prepared samples were evaluated. Tensile test conducted on the solid propellant cured for 7 days showed that increasing the proportional amount of DDI compared to TDI in the solid propellant formulation increases the elongation percentage and decreases the tensile strength, modulus, burning rate and pressure exponent (n). Considering that DDI also plays the role of a softening agent in the solid propellant formulation, increasing its amount in the solid propellant formulation will decrease the viscosity, causing a higher pot life.

Nano-aluminum double coated with copper and HTPB by one pot method and its catalysis on AP

ABSTRACT Organic-inorganic double-coated aluminum nanopowders (HTPB/Cu/nAl) were synthesized using a one-pot method. The morphology and structure were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy (FT-IR), and X-ray diffraction (XRD). The analysis revealed that Cu particles were uniformly dispersed around the nAl core, while HTPB formed a coating on the Cu/nAl surface. The thermal oxidation kinetics and catalytic effects on ammonium perchlorate (AP) were investigated through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The results indicated a 9% increase in the active aluminum content of the double-coated nanopowders compared to uncoated nAl, and a reduction in the average activation energy for thermal oxidation from 297.75 kJ·mol-1 to 218.85 kJ·mol-1. The HTPB coating enhanced the friction and impact sensitivity of the Cu/nAl particles. Adding 5% HTPB/Cu/nAl to AP advanced the low- and high-temperature decomposition peaks by 5°C and 40°C, respectively, while reducing the activation energy of AP from 85.61 kJ·mol-1 to 79.79 kJ·mol-1. This addition significantly influenced the thermal decomposition of AP, improving combustion efficiency and enhancing compatibility within composite propellant formulations.

Flame temperature and emissivity distribution measurement of solid propellant based on clustering analysis of multispectral radiation images.

To measure the combustion parameters of a solid propellant, this Letter researches the fitting method for flame temperature and emissivity based on multispectral images and proposes the particle swarm optimization-K-means (PSO-K-means) clustering optimization algorithm of a flame multispectral image. Considering the difference in flame radiation characteristics in different regions, the flame multispectral image is clustered, and spectra in different regions are analyzed and selected in different fitting bands to inverse temperature and emissivity. On this basis, the method is applied to measure solid propellant combustion parameters with different formulations. The measurement shows that the flame temperature is between 1700 and 2100 K, and the emissivity is concentrated in 0.1-0.5. Compared with temperature measurements obtained from tungsten-rhenium thermocouples, the relative deviation of multispectral imaging thermometry is less than 5%. The distribution characteristics of solid propellant combustion parameters with different formulations were analyzed, which provided important data support for evaluating combustion conditions and optimizing solid propellant formulations.

Research on the synthesis process and properties of dinitramide compounds for applications in propellants and explosives

Dinitramide compounds are characterized by a high oxygen and nitrogen content and the absence of halogens in their molecular structure, making them suitable for environmentally friendly new-generation propellants and explosives. This study outlines the optimization of the synthetic pathways for these compounds, including the preparation of guanylurea dinitramide (GUDN) via nitration and the synthesis of potassium dinitramide (KDN), ammonium dinitramide (ADN), and guanidinium dinitramide (GDN) through ion-exchange reactions. Additionally, the resulting dinitramide compounds were systematically evaluated for their physicochemical properties, ballistic characteristics, and spectral features. The findings demonstrate that these compounds exhibit high synthesis efficiency and possess properties conducive to their effective application in propellant and explosive formulations.

Manufacture of Solid Propellants Based on Renewable Succinic Acid Polyols

AbstractModern energy policies encourage the replacement of fossil fuels with a more sustainable type. Succinic acid is a promising renewable material that can react with ethylene glycol and 1,4‐butanediol in a two‐step polycondensation reaction to form hydroxylated polyesters. Copolymerization reactions were investigated to produce novel green binders for manufacture of solid propellants. The ester of the first step of polycondensation was used as a plasticizer in the propellant formulation. These products can be an alternative to binders of fossil sources, such as hydroxyl‐terminated polybutadiene (HTPB), frequently used as fuel of commercial propellants. Initially, analyses of Fourier transform infrared spectroscopy, nuclear magnetic resonance and gel permeation chromatography indicated the formation of polymeric products and adequate chain growth at reaction conditions. Then, the obtained copolymers were characterized by rheological analyses, which revealed that the processability of the copolymer materials was similar to that of the HTPB samples. Additionally, thermogravimetric analyses indicated that the copolymers presented good thermal stability below 200°C. Furthermore, differential scanning calorimetric (DSC) analyses indicated that the glass transition temperatures of the obtained copolymer samples ranged from −20 to −60°C, a suitable range for the intended use. Solid propellants were then prepared with solid loadings above 70 wt %, heat of combustion above 11,300 J g−1 and heat of explosion above 4,980 J g−1, which are compatible with values expected for solid propellants. Finally, oxygen balance calculations showed that the intrinsic oxygen content of the polyesters can allow the reduction of amounts of oxidizers in the final propellants.

Controlled Release of Diborane from Alkali Metal Borohydride using Ionic Liquid-Based Lewis Acids.

Alkali metal borohydrides present a rich source of energy dense materials of boron and hydrogen, however their potential in propellants has been hitherto untapped. Potassium borohydride is a promising fuel with high gravimetric energy density and relatively low sensitivity to air and moisture. Problems arise due to the dehydrogenation of the borohydride on heating with minimal energy release. Common methods to extract both boron and hydrogen by means of borane species involve direct reaction of boron trifluoride species with alkali borohydrides. However, these methods face storage and safety issues due to rapid release of diborane on mixing the reactants. We propose a method of diborane release through controlled release of boron trifluoride by means of a tetrafluoroborate based ionic liquid. The trifluoride is released from the ionic liquid at elevated temperatures and enables safe mixture of the reactants at room temperature. It was found that the reaction between borohydride and boron trifluoride proceeds well above room temperature with potassium borohydride releasing diborane and potassium fluoride. The reaction pathway shows a primary reaction releasing diborane and potassium fluoride and a second less energy efficient step leading to the formation of potassium tetrafluoroborate. A 3D printed propellant formulation was also tested.

Controlled Release of Diborane from Alkali Metal Borohydride using Ionic Liquid‐Based Lewis Acids

AbstractAlkali metal borohydrides present a rich source of energy dense materials of boron and hydrogen, however their potential in propellants has been hitherto untapped. Potassium borohydride is a promising fuel with high gravimetric energy density and relatively low sensitivity to air and moisture. Problems arise due to the dehydrogenation of the borohydride on heating with minimal energy release. Common methods to extract both boron and hydrogen by means of borane species involve direct reaction of boron trifluoride species with alkali borohydrides. However, these methods face storage and safety issues due to rapid release of diborane on mixing the reactants. We propose a method of diborane release through controlled release of boron trifluoride by means of a tetrafluoroborate based ionic liquid. The trifluoride is released from the ionic liquid at elevated temperatures and enables safe mixture of the reactants at room temperature. It was found that the reaction between borohydride and boron trifluoride proceeds well above room temperature with potassium borohydride releasing diborane and potassium fluoride. The reaction pathway shows a primary reaction releasing diborane and potassium fluoride and a second less energy efficient step leading to the formation of potassium tetrafluoroborate. A 3D printed propellant formulation was also tested.

A novel ADN/TANPDO supramolecular crystal with anti-hygroscopicity and high energy: A promising strategy to construct advanced propellant materials

Herein, encapsulating NH4+ ions through molecular self-assembly method has been employed to reduce the strong hygroscopicity of ADN (ammonium dinitramide). A novel ADN/TANPDO (2,4,6-triamino-5-nitropyrimidine-1,3-dioxide) supramolecular crystal with a 3:2 ratio was obtained using a rapid, green, efficient, and scalable self-assembly method. Compared with pure ADN, ADN/TANPDO supramolecular crystal exhibits a significantly lower hygroscopicity rate of 2.76 % (25 °C and 75 % relative humidity) and a lower impact sensitivity of 15 J, as well as a markedly higher specific impulse of 236 s. Additionally, the propellant formulation based on ADN/TANPDO supramolecular crystal presents high predicted energy with decreased content of HCl gas, making it a promising candidate for a high-energy and low-characteristic signal propellant component. Furthermore, this work offers a promising strategy to construct supramolecular crystals for solving the strong hygroscopicity of ADN and simultaneously assemble oxidizers with high-energy materials together at the molecular scale to achieve advanced propellant materials in the future.

Thermodynamic and propulsive characterization of nitro-substituted quadricyclane

This investigation delves into the potential of Octa-nitro Quadricyclane (ONQC), a nitro-substituted quadricyclane, as a next-generation energetic material. Employing a robust B3LYP-gCP-D3/6-31G(d) computational approach, the study evaluates key material properties of ONQC, including strain energy (700.2 kJ/mol), enthalpy of formation (668.6 kJ/mol), and density (2.08 g/cm³). These enhanced properties result in predicted increases of 124 % in detonation pressure and 49.5 % in detonation velocity compared to TNT, significantly surpassing the performance of conventional high-energy density materials. Additionally, ONQC's suitability as an energetic additive in bipropellant formulations was evaluated with NASA's Chemical Equilibrium with Applications (CEA) software. The primary focus was on bipropellant formulations employing kerosene-based fuels (RP-1, JP-10, JP-5, etc.) and liquid oxygen (LOX) as the oxidizer. Incorporating ONQC into propellant formulations provides substantial improvements in specific impulse and reduces oxidizer requirements. This makes ONQC a promising candidate for advancing propulsion technology.

Effect of aluminum and ammonium perchlorate particle sizes on the condensed combustion products characteristics of aluminized NEPE propellants

Aluminum (Al) is usually added to solid propellants to improve the combustion performance, however the condensed combustion products (CCPs) especially the large agglomerates generated from aluminum combustion can reduce the specific impulse of the engine, and result in two-phase loss, residue accumulation and throat liner ablation. Al and ammonium perchlorate (AP), as important components of NEPE propellants, can affect the formation process of the CCPs of aluminized NEPE propellants. To clarify the effect of Al and AP particle sizes on the properties of the CCPs of aluminized NEPE propellants, a constant-pressure quench vessel was adopted to collect the combustion products of four different formulations of NEPE propellants. It was found that the condensed combustion products are mainly divided into aluminum agglomerates and oxide particles, the diameter of the aluminum agglomerates of these four different formulations of NEPE propellants at 7 MPa was smaller than that in 3 MPa, and the shells of the aluminum agglomerates were smoother and the spherical shape was more perfect. X-ray diffraction analysis of the CCPs of the four NEPE propellants under 3 MPa revealed the presence of both Al and Al2O3. With the increase of the particle size of Al and AP, the oxidation degree of aluminum particles decreases. The particle size of the CCPs of the four different formulations of NEPE propellants under 1 and 3 MPa was analyzed by using a laser particle size analyzer, it is found that the increase of AP particle size is helpful to reduce the size of condensate combustion products. Based on the classical pocket theory, establishing a new agglomeration size prediction model, which can be used to predict the agglomeration size on the burning surface. Compared with the empirical model, the new agglomeration size prediction model is in good agreement with the experimental results.

Unraveling the Roles of Ionic Size and Hydrogen Bonding in Electric Field-Driven Ion Emission from Hydroxylamine Nitrate-Based Ionic Liquids.

Ionic size and hydrogen bonding (HB) may play significant roles in controlling ion emission from HAN (hydroxylamine nitrate)-based ionic liquids (ILs) but have received little attention. In this paper, the ion emission behavior and mechanism in an external electric field are meticulously investigated using the molecular dynamics (MD) method and density functional theory. We find that the higher the proportion of ionic HAN in the blend of ILs, the longer the delay time of the ion start-up emission. In the positive mode, cations can evaporate directly from the surface of the studied ILs and manifest exclusively as the [EMIM]+ monomers within the simulation time scale, whereas in the negative mode, a variety of complicated anion clusters are emitted. As a result, the average charge-to-mass ratio of the positively charged species remarkably exceeds that of the negatively charged species. This large difference is attributed to the relatively larger size of the [EMIM]+ ion and the absence of substantial HB interactions between the [EMIM]+ ion and any other monomer, leading to diminished binding energies. Conversely, the strong HB interactions, primarily constituted by N-H--O and O-H--O hydrogen bonds, are clearly found in the [EtSO4]--based and HAN-based clusters. In addition, the [NO3]- and [EtSO4]- ions tend to combine with the small-sized [HA]+ ions to form large anion clusters rather than with the [EMIM]+ ions. The energy decomposition results further elucidate that the orbital interaction plays a pivotal role in the [NO3]- and [EtSO4]--based clusters. The findings clearly elucidate the experimental phenomena observed in previous studies and have implications for the formulation of multimode IL propellants.

Minimizing Redundancy and Data Requirements of Machine Learning Potential: A Case Study in Interface Combustion.

The machine learning potential has emerged as a promising approach for addressing the accuracy-versus-efficiency dilemma in molecular modeling. Efficiently exploring chemical spaces with high accuracy presents a significant challenge, particularly for the interface reaction system. This study introduces a workflow aimed at achieving this goal by incorporating the classical SOAP descriptor and practical PCA strategy to minimize redundancy and data requirements, while successfully capturing the features of complex potential energy surfaces. Specifically, the study focuses on interface combustion behaviors within promising alloy-based solid propellants. A neural network potential model tailored for modeling AlLi-AP interface reactions under varying conditions is constructed, showcasing excellent predictive capabilities in energy prediction, force estimation, and bond energies. A series of large-scale MD simulations reveal that Li doping significantly influences the initial combustion stage, enhancing reactivity and reducing thermal conductivity. Mass transfer analysis also highlights the considerably higher diffusion coefficient of Li compared to Al, with the former being three times greater. Consequently, the overall combustion process is accelerated by approximately 10%. These breakthroughs pave the way for virtual screening and the rational design of advanced propellant formulations and microstructures incorporating alloy-formula propellants.

Identification of Isocyanate Number on IPDI and TDI Due to Storage Period and Their Impact on Composite Solid Propellant

Isocyanate compounds serve as a curing agent in the production of composite propellants, playing a crucial role in determining their characteristics. Due to its high reactivity with moisture, it is essential to determine the isocyanate number of stored samples after a specific duration. The investigation identified the isocyanate number of IPDI and TDI that had been held for 84 and 90 months. The FTIR analysis identified the presence of the NCO group at 2240 cm-1 for TDI and 2243 cm-1 for IPDI samples held for 84 and 90 months. The isocyanate number identification decreased by 1-2% after being stored for six months. This reduction in isocyanate quantity undoubtedly impacts the development of propellant compositions. The reduction in isocyanate content will alter the propellant formulation, leading to propellants with different characteristics due to its impact on the curing ratio (NCO/OH). The curing ratio greatly impacts the mechanical properties of composite propellant.

Superior Enhancement in Mechanical Properties of Polyurethane‐Based Multifunctional GAP Partially Grafted with Fluorinated Polyether via Catalyst‐Free Click Reaction

AbstractDifunctional glycidyl azide polymer (GAP) is an energetic binder promising for propellant formulations. The multifunctional fluorine‐containing GAP has been synthesized to enhance its mechanical properties. This work outlined multifunctional GAP partially grafted with 1,2,3‐triazole‐5‐(α‐hydroxyl)‐fluorinated polyether (GAP‐g‐3F) synthesized by thermal and catalyst‐free azide‐alkyne cycloaddition reaction, in which the azide groups were from GAP and electron‐deficient alkynes from β‐propargyl‐α‐hydroxyl poly (tri‐fluoropropane glycidyl ether) (PHP3F). PHP3F was synthesized via the typical cationic ring‐opening polymerization of 2‐((2,2,2‐trifluoroethoxy) methyl) oxirane and propargyl alcohol as the initiator. The chemical structures, molecular weight, and thermal properties were characterized by FTIR, NMR, GPC, DSC, and TGA, respectively. HNMR results showed that 8 % of total azide groups in GAP were grafted. GAP‐g‐3F had a slightly higher glass transition temperature than that of GAP. The results of TGA showed that GAP‐g‐3F had suitable thermal decomposition resistance up to 200 °C. The thermal properties, mechanical properties, cross‐linking network structures, and microstructures of the polyurethane networks cured with hexamethylene diisocyanate trimer as a crosslinking agent were determined and compared by TGA, universal tensile test, swelling measurement, and SEM, respectively. The initial decomposition temperature of GAP‐g‐3F‐based polyurethane networks (GAP‐g‐3F‐PU) was around 220 °C, thus meeting the requirements for propellants. In addition, GAP‐g‐3F‐PU exhibited superior mechanical properties, showing an almost twelvefold increase in tensile strength to 16.9 MPa compared with difunctional GAP‐PU with 1.4 MPa tensile strength. The results of the swelling measurement revealed that the GAP‐g‐3F‐PU sample showed a higher crosslinking density in comparison to the GAP‐PU sample. SEM results indicated that the multifunctional fluorine‐containing GAP could enhance compatibility between the soft and hard segments of polyurethanes, leading to a decrease in their separation degree. This finding showed that the synthesis of a multifunctional GAP partially grafted with fluorinated polyether via a triazole ring may be a promising solution to decrease the separation degree increase of PUs, thereby improving the mechanical properties.

Research on the energy performance of gun propellant formulations containing 3,5-bis(azidomethyl) isoxazole (BAMIO)

Research on the energy performance of gun propellant formulations containing 3,5-bis(azidomethyl) isoxazole (BAMIO)

Enhancing combustion performance of solid propellants using synergistic effect of energetic metal–organic framework with cage-like [Bi6(µ3-O)3(µ3-OH)5] clusters and copper-iron hetero-metallic compound

This study explores the potential of energetic metal–organic frameworks (E-MOFs) to enhance the combustion performance of solid propellants. A {[Bi6O3(tza)5(NO3)2(OH)5]·H2O}n (Bi-MOF) incorporating the energetic ligand tetrazole-1-acetic acid (Htza) was synthesized and evaluated for structural characteristics and properties. The catalytic thermal decomposition of cyclotrimethylene trinitramine (RDX) and cyclotetramethylene tetranitramine (HMX) by mixed systems was investigated. These systems consisted of Bi-MOF and copper-iron hetero-metallic compound ({[CuFe3O(tza)6(H2O)3]·Cl·(NO3)2·4H2O}n, CuFe-MOF), previously reported by our group in different ratios. The effect of the mixed system with the highest synergy index on the combustion performance of composite modified double-base propellant (RDX-CMDB) and nitrate ester plasticized polyether propellant (HMX-NEPE) was investigated. The impact of varying carbon black (CB) contents on the catalytic performance of the mixed system was also examined. The results showed that Bi-MOF exhibits good thermal stability (Tdec = 226.9 °C) and insensitivity (IS>40 J, FS>360 J). The mixed system, comprising Bi-MOF and CuFe-MOF in a 2:1 ratio (M2), exhibited the highest synergistic indices (3.35 and 3.24) on thermal decomposition for RDX and HMX. RDX-CMDB and HMX-NEPE propellant formulations containing M2 and a small amount of CB exhibited significant improvements in combustion performance. RDX-CMDB propellant exhibited up to an 80.6 % increase in burning rate and up to a 59.6 % reduction in pressure index. The pressure indices of NEPE without and with aluminum were reduced from 0.65 and 0.50 to 0.38 and 0.40, respectively (10–20 MPa, 1–20 MPa). These findings highlight the promise of the mixed system, formed by Bi-MOF and CuFe-MOF, as a potential combustion catalyst for RDX-CMDB and HMX-NEPE propellants.

Combustion behavior of NMP-001, a nitromethane-based green rocket propellant

Hydrazine’s carcinogenic and toxic nature makes its use in space propulsion expensive and necessitates careful launch campaign planning, which may cause delays. One already established alternative is to use energetic salt-based ionic solution propellants. However, the costs remain high because these salts are costly and highly regulated energetic materials. Additionally, propellants based on these energetic salts produce much higher temperatures during decomposition and combustion, as is the case for hydrazine. Consequently, expensive refractory metal-based alloys and high-temperature oxidation-resistant catalytic reactors must be used, which further drives up the costs. Alternatively, hydrogen peroxide may be used, though only in applications with a low specific impulse requirement. This study explores an alternative approach: using nitromethane, a commonly available laboratory solvent. NMP-001 is a nitromethane-based monopropellant that contains additives that allow for low-pressure combustion and reduce sensitivity to mechanical stimuli. Multiple combustion chamber configurations with varying characteristic lengths were tested in rocket combustion experiments. With the 11.5 m L∗-configuration, a 15.1 bar low-pressure limit could be determined. The 7.3 and 5.0 m L∗-configurations yielded a 16.2 and 28.3 bar low-pressure combustion limits, respectively. These outcomes are significantly below the 30 bar limit reported in the literature. Despite using only a simple heat-sink combustion chamber with a non-sophisticated injector element and a non-optimized propellant formulation, combustion was 83 to 95 % efficient with a C* ranged between 1133 to 1302 m/s. These figures are higher than for hydrogen peroxide and are comparable to the theoretical performance of state-of-the-art green liquid monopropellants.

Application of Lee–Tarver Model for Energetic Materials Safety Assessment Utilized in Aerospace Applications

Energetic materials, essential for rocket propulsion, play a crucial role in aerospace systems. These materials lack sufficient safety assessments and pose significant risks to life and infrastructure. The slow progress in this field is hindered by prohibitively high experimental costs and the inherently destructive nature of these experiments. This study aimed to evaluate modeling-based safety assessments, primarily utilizing the Lee–Tarver model. It specifically addressed the threat posed by shaped charges during transportation. Experimental analyses employed 50 mm JH-2 shaped charges, targeting RDX-based JH-2 formulation, since RDX is widely used in various rocket motor propellant formulations. TNT was also used to enhance the validation of the Lee–Tarver model findings. Various logistical configurations were explored, testing steel container walls ranging from 10 mm thickness to reinforced walls of 50 mm, 60 mm, and 65 mm steel. Comparative analysis with experiments reinforced the accuracy of the Lee–Tarver model’s numerical predictions. Both simulations and experiments affirmed that a 65 mm steel protection suffices for the safe transportation of RDX-based JH-2 formulations and TNT within a 10 mm storage box in logistical setups. Furthermore, this study emphasizes the Lee–Tarver model’s reliability for most energetic materials safety assessments, while acknowledging certain limitations.

Eco‐friendly chemically crosslinked solid composite propellants via catalyst‐free azide‐alkyne cycloaddition

AbstractWe have innovatively formulated solid propellants by employing a catalyst‐free azide‐alkyne cycloaddition approach, steering away from the conventional urethane curing system reliant on moisture‐sensitive isocyanate compounds. These conventional systems exhibits poor compatibility with the eco‐friendly ionic oxidizers. Azide polymers, including polycaprolactone ether (PCE), polycaprolactone (PCL), and polyethylene glycol (PEG) were incorporated, with their terminal hydroxyl groups strategically modified with azides. Additionally, glycidyl azide polymer (GAP), characterized by an abundance of azides in its side chains, was introduced. For polybutadiene‐based solid propellants, a departure from the norm was pursued. We employed polybutadiene (PB) terminated with electron‐deficient alkynes(propiolate), synthesized through a urethane reaction involving an unsymmetric divalent chain‐linker containing both isocyanate and propiolate functionalities with hydroxyl‐terminated polybutadiene (HTPB). This approach diverged from the common practice of modifying other polymers with azides at the terminal. To ensure the attainment of optical mechanical properties in azide‐terminated polymer‐based solid propellants, trivalent propiolate curatives were judiciously combined with divalent propiolate curatives in an appropriate blend ratio. A meticulously synthesized series of polymeric bonding agents, designed to establish chemical links between solid oxidizers and polymer binder, revealed the idenfication of exceptional bonding agents. These agents played a pivotal role in delivering outstanding mechanical properties in solid propellants based on ammonium perchlorate (AP) and nitramine‐typed oxidizers. GAP‐based solid propellants were meticulously prepared, incorporating both urethane moieties at the terminal and triazole moieties at the side chains. Trivalent azide‐terminal curatives were introduced for crosslinking PB terminated with propiolates. Generally, triazole‐curing system resulted in solid propellants exhibiting notably higher burning rates compared to those crosslinked through urethanes. In summary, this research presents a sophisticated approach to the formulation of solid propellants, emphasizing a departure from conventional systems, strategic polymer modifications, and the meticulous synthesis of bonding agents to achieve superior mechanical properties and burning rates.

Effect of pressure, Mg content and AP size on the microscale flame structure of Mg-based propellant

The Mg-based propellant is considered to be a promising fuel for underwater propulsion, but the mechanism of the change of the burning rate is unclear. The Mg-based propellant was divided into two parts on the basis of the BDP multi-flame model: large-size oxidizer particle and pseudo-propellant consisting of fine oxidizer and other components, and the micro steady-state combustion model of Mg-based propellant was established. Quantitatively analysis on the gas-phase multi-flame structure was performed, which focused on the effect of pressure, Mg content, and oxidizer particle size on the burning rate. This model was verified by the results of combustion experiments on ammonium perchlorate (AP) /hydroxyl‑terminated polybutadiene (HTPB) composite propellant and Mg-based propellant, and the mean absolute percentage error between the burning rate obtained from the simulation and the experimental measurements was less than 5%. Results indicated that the flame structure of Mg-based propellant exhibited typical BDP flame characteristic. As pressure increased from 1 MPa to 4 MPa, the premixed AP flame and the preliminary diffusion flame were closer to the burning surface, which enhanced the heat feedback. And accordingly, the burning rate raised from 5.93 mm/s to 9.79 mm/s. Mg content mainly affect the combustion process of the pseudo-propellant. The premixed flame above the pseudo-propellant gradually disappeared as the Mg content increased from 15% to 63%, which led the burning rate to decrease from 17.45 mm/s to 7.83 mm/s. AP particle size affected the effectiveness of the preliminary diffusion flame on the burning surface and resulted in a change in the burning rate. These findings can provide theoretical guidance for the design of Mg-based propellant formulations.