Several aluminum nanopowders were examined and compared with the final goal to evaluate their application in solid rocket propulsion. A detailed investigation of pre-burning properties by the Brunauer-Emmet-Teller method, electron microscopy, X-ray diffraction, and X-ray photoelectron spectroscopy was carried out. Ballistic properties and the combustion mechanism of several aluminized propellant formulations were investigated. In particular, aggregation and agglomeration of metal particles at and near the burning surface were analyzed by high-speed high-resolution color digital video recordings. All tested nano-powders are of Russian production; their physical characterization was carried out at the Istituto Donegani (Novara, Italy); ballistic studies were performed at the Solid Propulsion Laboratory (Milano, Italy) using laboratory and, for comparison, industrial composite propellants based on ammonium perchlorate as an oxidizer. Results obtained under a fair variety of operating conditions typical of rocket propulsion indicate, for increasing nano-Al mass fraction or decreasing nano-Al size, larger steady burning rates with essentially the same pressure sensitivity. While aggregation and agglomeration phenomena still occur, their significance may be reduced by using nano-Al instead of micro-Al.

The characterization of several differently sized aluminium powders, by BET (specific surface), EM (electron microscopy), XRD (x-ray diffraction), and XPS (x-ray photoelectron spectroscopy), was performed in order to evaluate their application in solid rocket propellant compositions. These aluminium powders were used in manufacturing several laboratory composite solid rocket propellants, based on ammonium perchlorate (AP) as oxidizer and hydroxilterminated polybutadiene (HTPB) as binder. The reference formulation was an AP/HTPB/Al composition with 68/17/15% mass fractions respectively.

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Following a detailed literature survey on the fracture-mechanics properties of solid rocket propellants, this paper reports on an innovative set of fracture tests performed on a composite solid propellant based on ammonium perchlorate hydroxyl-terminated polybutadiene. After a short summary on standard linear–viscoelastic mechanical characterization, results on both linear–elastic fracture-mechanics (characterized by the fracture toughness KIC) and nonlinear fracture-mechanics (characterized by GF) tests are reported. Test results for linear–elastic fracturemechanics simulations have been obtained using middle-tension specimens. A practical methodology to separate the\ud amount of strain energy lost through viscous processes from other sources is given and provides an effective method to apply the toughness-test validity criteria of the American Society for Testing and Materials E399 norm to propellants and other thermoviscoelastic materials. Measurements to determine the linear fracture-mechanics properties of the propellant have been carried out applying the wedge-splitting test methodology. Master curves for the toughness, the critical crack-opening displacement, and the fracture energy have been generated to correlate test\ud data. Results are coherent with Shapery’s theory of fracture for viscoelastic materials. Results can be used within finite element simulations to assess the safety and integrity of a solid-propellant rocket motor under various loads, such as thermal cycling and ignition, assuming stationary conditions

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Following a comprehensive literature survey about use of Al nanopowders in a range of HEM applications — including rocket propulsion, pyrotechnics, and explosives - a through treatment is offered of the ideal and delivered thermochemical performance of the most interesting metallic ingredients to augment solid and hybrid rocket propulsion. The particular but fundamental class of nAl powders is then investigated in detail: critical issues such as coating and characterization of the powders, rheological and mechanical properties, combustion and ballistic behavior are all examined under a variety of operating conditions. Although attractive for fundamental studies and much used in laboratory experiments, no rocket propulsion operational systems are yet reported in use for nAl powders. Loss of active metal, cold cohesion, and poor propellant castability globally overcome advantages such as increased burning rate (easily achievable by other ways) and reduced specific impulse losses associated with 2P flow (thanks to less agglomeration with respect to the corresponding micrometric powders). Use of dual metallic fuels, by properly blending μAl and nAl, and/or modification of the natural properties of nAl particles, by suitable coatings, represent two possible ways to exploit the potential of nanopowders. Several approaches are also discussed so as to improve dispersion and mechanical properties of solid propellants or solid fuels containing nAl. Overall, a good control of particle size, metal content, and dispersion is a crucial requirement for successful applications of nanoingredients in propulsion

The cocrystallization of high-energy explosives has attracted great interests since it can alleviate to a certain extent the power-safety contradiction. 2,4,6,8,10,12-hexanitro-2,4,6,8,10,12-hexaaza-isowurtzitane (CL-20), one of the most powerful explosives, has attracted much attention for researchers worldwide. However, the disadvantage of CL-20 has increased sensitivity to mechanical stimuli and cocrystallization of CL-20 with other compounds may provide a way to decrease its sensitivity. The intermolecular interaction of five types of CL-20-based cocrystal (CL-20/TNT, CL-20/HMX, CL-20/FOX-7, CL-20/TKX-50 and CL-20/DNB) by using molecular dynamic simulation was reviewed. The preparation methods and thermal decomposition properties of CL-20-based cocrystal are emphatically analyzed. Special emphasis is focused on the improved mechanical performances of CL-20-based cocrystal, which are compared with those of CL-20. The existing problems and challenges for the future work on CL-20-based cocrystal are discussed.

Several industrial- and research-type composite solid propellants containing different nano metric metal oxide catalysts (Fe2O3, Co3O4, CuO, and PbO) with similar nominal composition, were prepared and experimentally analyzed. The effects of different nano-sized metal oxide catalysts on the rheological properties and hazardous properties were investigated. The strand burning rate and the associated combustion flame structure of composite propellants were determined. The results show that the nano-sized metal oxide powders can be sufficiently dispersed in hydroxyl terminated polybutadiene binder. The propellant formulations containing nano metal oxide particles are sensitive to impact and friction except for the base propellant without nano-sized powders, which is less sensitive to friction as compared to the other compositions. The nano-sized metal oxide additives can affect the combustion behavior and increase the burning rate of propellants compared with the reference propellant composition