Boron nanoparticles prepared by milling in the presence of a hypergolic energetic ionic liquid (EIL) are suspendable in the EIL and the EIL retains hypergolicity leading to the ignition of the boron. This approach allows for incorporation of a variety of nanoscale additives to improve EIL properties, such as energetic density and heat of combustion, while providing stability and safe handling of the nanomaterials.

Complexation of amines with borane converts them to hypergols or decreases their ignition delays (IDs) multifold (with white fuming nitric acid as the oxidant). With consistently low IDs, amine-boranes represent a class of compounds that can be promising alternatives to toxic hydrazine and its derivatives as propellants. A structure-hypergolicity relationship study reveals the necessary features for the low ID.

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Hydrochloric acid (HCl) pollution from perchlorate based propellants is well known for both launch site contamination, as well as the possible ozone layer depletion effects. Past efforts in developing environmentally cleaner solid propellants by scavenging the chlorine ion have focused on replacing a portion of the chorine-containing oxidant (i.e., ammonium perchlorate) with an alkali metal nitrate. The alkali metal (e.g., Li or Na) in the nitrate reacts with the chlorine ion to form an alkali metal chloride (i.e., a salt instead of HCl). While this technique can potentially reduce HCl formation, it also results in reduced ideal specific impulse (ISP). Here, we show using thermochemical calculations that using aluminum-lithium (Al-Li) alloy can reduce HCl formation by more than 95% (with lithium contents ≥15 mass%) and increase the ideal ISP by ∼7s compared to neat aluminum (using 80/20 mass% Al-Li alloy). Two solid propellants were formulated using 80/20 Al-Li alloy or neat aluminum as fuel additives. The halide scavenging effect of Al-Li propellants was verified using wet bomb combustion experiments (75.5±4.8% reduction in pH, ∝ [HCl], when compared to neat aluminum). Additionally, no measurable HCl evolution was detected using differential scanning calorimetry coupled with thermogravimetric analysis, mass spectrometry, and Fourier transform infrared absorption.

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The microexplosive nature of multicomponent liquid fuels has been both studied and fielded to decrease droplet residence times and increase completeness of combustion. However, little work has focused on investigating microexplosive metal fuels to enhance the metal fuel combustion efficiency in traditional energetic material formulations. Microscopic surface videography was performed on two solid propellant formulations, one using aluminum (baseline) and the other with 80/20 wt.% Al-Li alloy as fuel additives. It was observed that the propellant combustion with neat aluminum formed large molten droplets at the surface as aluminum particles agglomerate, which is a well-known problem with aluminized propellants. In contrast, the Al-Li propellant formed an Al-Li melt-layer on the propellant surface during combustion. Droplets were ejected from the surface melt-layer through dispersive boiling. Above the surface, further dispersive boiling is observed from the ejected droplets and droplet-shattering microexplosions are also observed. These dynamics are thought to be a result of a large disparity in volatility (i.e., boiling points) between the metals in the molten alloy and the large Lewis number in the droplet, so that superheating occurs before the more volatile component (here Li) can diffuse to the surface. A Lewis number of 7440 was estimated for molten 80/20 wt.% Al-Li alloy, which is nearly three orders of magnitude larger than typical multicomponent liquid hydrocarbon droplets that microexplode, suggesting a higher propensity for molten droplet microexplosions. This would also indicate that a smaller amount of the volatile component might be necessary for microexplosions and dispersive boiling than observed for liquid hydrocarbon fuels. These dynamics are important for metal fuel applications, because injectors cannot be used to decrease droplet size in a metallized energetic material formulation.

Aluminum-water reactions have been proposed and studied for several decades for underwater propulsion systems and applications requiring hydrogen generation. Aluminum and water have also been proposed as a frozen propellant, and there have been proposals for other refrigerated propellants that could be mixed, frozen in situ, and used as solid propellants. However, little work has been done to determine the feasibility of these concepts. With the recent availability of nanoscale aluminum, a simple binary formulation with water is now feasible. Nanosized aluminum has a lower ignition temperature than micronsized aluminum particles, partly due to its high surface area, and burning times are much faster than micron aluminum. Frozen nanoscale aluminum and water mixtures are stable, as well as insensitive to electrostatic discharge, impact, and shock. Here we report a study of the feasibility of an nAl-ice propellant in small-scale rocket experiments. The focus here is not to develop an optimized propellant; however improved formulations are possible. Several static motor experiments have been conducted, including using a flight-weight casing. The flight weight casing was used in the first sounding rocket test of an aluminum-ice propellant, establishing a proof of concept for simple propellant mixtures making use of nanoscale particles.