Enhancing the Ignition and Combustion Performances of Solid Propellants Incorporating Al Particles Inside Oxidizers

The combustion efficiency of Al plays a critical role in the combustion of high-energy aluminum-based solid propellants. For traditional formulations, the Al powders are dispersed in the binder matrix, leading to limited contact with the oxidizers and hence usually insufficient combustion and higher values of the pressure exponent. In this paper, various core–shell structural Al/oxidizer composites such as Al@HMX, Al@AP, and AP@Al have been prepared by a spray-drying technique based on which solid propellants with precise interfacial control between Al particles and oxidizers were realized. Compared to the control sample, the modified propellants have a greater heat of explosion of 5890 J g^–1 (15% higher) and a reduced ignition delay time of 58 ms (65% decrease). Without changing the content of components, the burn rates of propellants can be easily modulated by tuning the interfacial contact of Al and oxidizers, where it varies in a wide range of 4.56–5.79 mm s^–1 at the same pressure of 1 MPa. After introducing Al/oxidizer composites, the lowest pressure exponent of 0.19 within 1–15 MPa could be achieved by using Al@HMX and AP@Al composites. The agglomeration of Al was also inhibited by using Al/oxidizer composites, and the mechanism can be interpreted by using a classical “pocket” model. Moreover, the improved combustion efficiency of the solid propellants was verified by a noticeable reduction in the unreacted Al content.