Ammonium perchlorate (AP) is a common oxidant in solid propellants, and its thermal decomposition characteristics at low temperatures (less than 240 °C) are key to the study of the thermal safety of propellants. Here, the low-temperature thermal decomposition characteristics of AP were investigated at 230 °C. The micromorphology of the low-temperature decomposition residues was characterized by scanning electron microscopy and 3D nano-computed tomography in order to analyse the evolution of microscopic pore structures, and the effect of the AP pore structure on combustion performance was then tested and analysed with a homemade closed bomb. The results demonstrate that the low-temperature decomposition of AP first occurs near the surface of the particles, simultaneously starting at multiple points and forming pores, and then gradually expands towards the interior until almost all of the pores connect with one other. Compared with ordinary AP, porous AP has a significantly improved combustion rate. When the ratio of porous AP to Al was 80:20, the peak pressure in the closed bomb was increased by 2.7 times; the rate of change in peak pressure increased 34 times, leading to a higher reaction speed and higher reaction intensity, and a typical explosion reaction occurred.
To study the design method and pressure relief effect of the mitigation structure of a shell under the action of thermal stimulation, a systematic research method of theoretical calculation-simulation-experimental verification of the mitigation structure was established. Taking the shelled PBX charge as the test material, the pressure relief area that can effectively reduce the reaction intensity of the charge is obtained by theoretical calculation. The influence of the pressure relief hole area, distribution mode, and other factors on the pressure relief effect is calculated by simulation. The pressure relief effect of the mitigation structure was verified by the low-melting alloy plug with refined crystal structure for sealing the pressure relief hole and the cook-off test. The research results show that the critical pressure relief area is when the ratio of the area of the pressure relief hole to the surface area of the charge is AV/SB = 0.0189. When the number of openings increases to 6, the required pressure relief coefficient decreases to AV/SB = 0.0110; When the length/diameter ratio is greater than 5, the opening at one end cannot satisfy the reliable pressure relief of the shell. The designed low-melting-point alloy mitigation structure can form an effective pressure relief channel. With the increase in AV/SB from 0.0045 to 0.0180, the reaction intensity of the cook-off bomb is significantly reduced in both fast and slow cook-off, which improves the safety of the charge when subjected to unexpected thermal stimulation.
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