Boron powder is a kind of metal fuel with high gravimetric and volumetric calorific values, which has been widely used in military fields such as solid propellants, high-energy explosives, and pyrotechnics. However, the easily formed liquid oxide layer can adhere to the surface of boron powder and react with the hydroxyl (-OH) group of hydroxyl-terminated polybutadiene (HTPB) binder to form a gel layer that is detrimental to propellant processing and restricts the complete oxidation of boron powder. Therefore, to improve the combustion efficiency of boron powder, the ignition and combustion mechanisms of boron powder have been studied, and surface coating modification strategies have been developed by researchers worldwide, aiming to optimize the surface properties, improve the reaction activity, and promote the energy release of boron powder. In this review, recent studies on the ignition and combustion mechanisms of boron powder are discussed. Moreover, the reported boron powder coating materials are classified according to the chemical structure and reaction mechanism. Additionally, the mechanisms and characteristics of different coating materials are summarized, and the mechanism diagrams of fluoride and metal oxide are provided. Furthermore, promising directions for modification methods and the potential application prospects of boron powder are also proposed.

/pdf/high-calorific-values-boron-powder-ignition-and-combustion-3dc38ntn.pdf

High Calorific Values Boron Powder: Ignition and Combustion Mechanism, Surface Modification Strategies and Properties

New micro-unit composite fuels Al@AP with different mass ratios of Al and AP are designed, prepared, and added to solid propellants in place of the original aluminum powder. Through Thermogravimetric Analysis- Differential scanning calorimetry- Mass Spectrometry (TG-DSC-MS), laser ignition experiment, thermocouple temperature measurement, burning rate test, and combustion diagnostic, we study how Al@AP affects the ignition, combustion, and agglomeration properties of solid propellants. The results indicate that the increase of Al content of Al@AP can promote the advance of thermal decomposition of AP. As the AP content increases in Al@AP, the ignition delay time of Al@AP decreases by three times, and the mass burning rate increases by almost five times. At the same time, Al@AP significantly improves the burning rate and temperature gradient. When compare to the baseline propellant, Al@AP-containing propellants present a maximum increase in burning rate of 33% at low pressures and 19% at high pressures. In terms of agglomeration reduction, the number of large-size agglomerates in the CCPs of propellants containing Al@AP is reduced, the average particle size decreases by 78%, and the combustion efficiency increases to 99.34%. A mechanism is proposed to explain how the micro-unit composite fuel Al@AP alters propellant combustion and agglomeration. In summary, Al@AP provides excellent control over ignition, combustion, and agglomeration characteristics. This study provides guidance on the application and development of new aluminum-based composite fuels used in solid propellants. 

Controlling the combustion and agglomeration characteristics of solid propellants via new micro-unit composite fuel Al@AP

Hollow energetic microspheres have attracted great attention in the field of materials due to their wide application potential. However, scalable, simple, and low-cost production methods have not been achieved yet. In this study, using nitrocellulose (NC) as a binder, hollow and porous hollow CL-20 microspheres were prepared by the assist of microjet droplet technology. The effects of receiving liquid temperature, solution concentration, and solvent type on the morphology, particle size, shell thickness, and pore size of the CL-20 microspheres were systematically investigated. Furthermore, the influences of shell thickness and pore size on the dispersibility, crystal structure, thermal decomposition, mechanical sensitivity, and combustion behavior of CL-20 microspheres were further studied. The results showed that precise control over the shell thickness and pore size of CL-20 microspheres could be achieved by adjusting the process parameters. Compared to raw CL-20, the CL-20 microspheres exhibited excellent dispersibility and improved thermal and safety performance (raw CL-20 vs CL-20 microspheres, 40.3° vs 27.1° ∼ 29.1°; 240.4℃ vs 241.1 ∼ 246.2℃; 2 J vs 25 ∼ 32.5 J). Ignition experiments demonstrated that the hollow and porous hollow structures significantly enhanced the combustion flame of CL-20, shortened the burning time, and thereby improved energy release efficiency. This preparation method is simple and efficient, providing a new approach for the fabrication of multi-structured hollow energetic microspheres. 

Regulating hollow structure of CL-20 microspheres using microjet droplet technology to enhance safety and combustion performance

Preparation and characterization of Al@TKX-50@NC composite microspheres by electrospray

Synthesis and mechanistic exploration of interfacial control and enhanced catalysis for improving thermal decomposition of AP in Al@AP-Fe2O3 composites

Effect of the microporous structure of ammonium perchlorate on thermal behaviour and combustion characteristics

In this study, fluorinated polyurethane (FPU) was prepared from dialcohol-terminated perfluoropolyether as a soft segment; isophorone diisocyanate (IPDI) as a curing agent; 1,2,4-butanetriol (BT) as a crosslinker; and 1,4-butanediol (BDO) as a chain extender. Fourier transform infrared spectroscopy (FTIR) and 1H NMR were used to characterize the structure of the FPU. The mechanical properties of the FPUs with different BDO and BT contents were also measured. The tensile strength and breaking elongation of the optimized FPU formula were 3.7 MPa and 412%, respectively. To find out the action mechanism of FPU on Al, FPU/Al was prepared by adding Al directly to FPU. The thermal decomposition of the FPU and FPU/Al was studied and compared by simultaneous differential scanning calorimetry-thermogravimetry-mass spectrometry (DSC-TG-MS). It was found that FPU can enhance the oxidation of Al by altering the oxide-shell properties. The combustion performance of the FPU propellant, compared with the corresponding hydroxyl-terminated polyether (HTPE)-based polyurethane (HPU) propellant, was recorded by a high-speed video camera. The FPU propellants were found to produce smaller agglomerates due to the generation of AlF3 in the combustion process. These findings show that FPU may be a useful binder for tuning the agglomeration and reducing two-phase flow losses of aluminized propellants.

/pdf/influence-of-fluorinated-polyurethane-binder-on-the-1me8awnr.pdf

Influence of Fluorinated Polyurethane Binder on the Agglomeration Behaviors of Aluminized Propellants

Nano-boron, as a potential high-energy additive due to its high calorific value, is widely studied in propellants, explosives, and thermites. However, the unexpected agglomeration of surface oxidation hinders its further application, especially in the casting of energetic materials. The fluorine-modified nano-boron nB@F2603 and nB@F2603@CL-20 preagglomerated microspheres were prepared by electrospray to improve the ignition and combustion reactions and the rheological properties of boron-containing casting systems. Sphericity microspheres could be obtained by controlling the voltage and propulsion rate. The morphology and elemental distribution of the microspheres were characterized by the scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffractometer (XRD). Results showed that the particle size of the microspheres ranged from 4 to 14 µm. Boron, fluorine and nitrogen were uniformly distributed on the surface of the microspheres. XRD results showed that CL-20 in nB@F2603@CL-20 microspheres was β-crystal. The thermal reaction properties were studied by differential scanning calorimetry, thermogravimetry and mass spectrometry (TG-DSC-MS), oxygen bomb calorimeter, laser ignition, and volume combustion cell test. Results showed that F2603 could significantly promote the ignition and combustion of nano-boron, causing higher energy release and pressurization rates, and lower ignition temperature. Adding CL-20 to the microspheres could also greatly promote the reaction rates and energy release. The hydrophobicity and corrosion resistance of the structures were also studied, and results showed that the preagglomerated microspheres had good stabilities. Therefore, fluorine-containing nB@F2603 and nB@F2603@CL-20 microspheres might be used in composite energetic materials, replacing nano-boron.

/pdf/preparation-and-energy-release-properties-of-nb-f2603-cl-20-1saq5mqg.pdf

Preparation and Energy Release Properties of nB@F2603@CL-20 Microspheres by Electrospray

The properties of Sn–Zn–Al–La fusible alloy for mitigation devices of solid propellant rocket motors

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