In this paper, the RDX/expanded graphite (EG) intercalation composites were prepared by solvent/anti-solvent process to recrystallize RDX crystals into the holes, gaps and grooves of EG with controllable embedding ratio (maximum 87.0 wt%) and crystal size. RDX in the composites was in the most stableα-phase, which was benefit for its further application in the military industry. The stability and sensitivity of RDX were improved with higher melting and thermolysis temperature, activation enthalpy (ΔH
≠), critical temperature of thermal explosion (T
b) and lower mechanical sensitivity. The advanced half-coated parallel multi-sandwiches microstructure of RDX/EG intercalation composites possessed two effects: (i) high heat conduction and (ii) hot spots isolation of the carbon microstructure, which were the key to higher performance.
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