The present disclosure relates to three-dimensional (3D) printed fluoropolymer-based energetic compositions and 3D printing methods for making the 3D printed fluoropolymer-based energetic compositions.

The invention relates to a cast explosive composition comprising a polymer-bonded explosive and a defoaming agent, and to a process for reducing the number and/or total volume of voids in a cast explosive composition comprising the steps of: combining a polymer-bonded explosive and a defoaming agent; and casting the explosive composition. The defoaming agent may be used for reducing the number and/or total volume of voids in a cast explosive composition and the cast explosive composition may be used in an explosive product.

A process for mixing two materials using acoustic energy. A first material and a second material are placed within a mixing vessel and acoustic energy is transferred to the vessel. The first material has a plurality of particles with porosity and the second material may or may not be a polymeric liquid. The acoustic energy mixes the first material and the second material, the second material coats the first material, and shear forces are created that force the second material into at least a portion of the porosity of the first material.

A combustible element includes regions of fuel material interspersed with regions of oxidizer material. The element may be made by additive manufacturing processes, such as three-dimensional printing, with the fuel material regions and the oxidizer material regions placed in appropriate locations in layer of the combustible element. For example, different extruders may be used to extrude and deposit portions of a fuel filament and an oxidizer filament at different locations in each layer of the combustible element. The combustible element may define a combustion chamber within the element, where combustion occurs when the combustible element is ignited. The fuel material and the oxidizer material may be selected, and their relative amounts may be controlled, such that desired relative amounts of fuel and oxidizer are present for combustion with desired characteristics, such as combustion rate.

The present invention relates to a method and device for emulsifying emulsion explosive: an oil phase and a part of a water phase having undergone split-flow enter a first stage coarse emulsion mixer; after mixing, the mixture together with a part of the water phase having undergone second stage split-flow enters a second stage coarse emulsion mixer; the obtained mixture together with a part of the water phase having undergone third stage split-flow enters a third stage coarse emulsion mixer for mixing; forming a coarse emulsion matrix after multiple stages of mixing, and finally completing emulsification after mixing in a multi-stage fine emulsion mixer. The method and device mix the water phase with the oil phase multiple times according to a desired ratio, thus greatly reducing the stored explosive, with no mechanical stirring or shearing, with no heat accumulation, and with low pressure, without requiring matrix pumping, thus enhancing safety.

An energetic thermoplastic filament comprising an energetic material bound within a thermoplastic matrix and methods for the fabrication of an energetic thermoplastic filament are disclosed. The energetic material comprises an energetic material selected from an explosive, a propellant, a pyrotechnic, an oxidizer, or combinations thereof. The thermoplastic comprises a TPE, ETPE, or combinations thereof. The thermoplastic filaments may be formed by extrusion. The energetic thermoplastic filaments are particularly suitable for additive manufacturing by thermal FDM style 3D printing systems.

A product includes a three-dimensional scaffold structure having an open cell geometry with interconnected channels for allowing continuous communication throughout a volume of the scaffold structure. The scaffold structure is configured to enhance mechanical strength of an energetic material. A fuel material is present in the scaffold structure and/or a second material is coupled to the scaffold structure. The fuel material is configured to increase an output of energy release relative to an output of energy release from the scaffold structure having the fuel material not present.

A composite explosive product, wherein its composition expressed as percentages by weight includes 85% to 92% of organic energetic charges; the organic energetic charges a) being selected from charges of octogen (HMX), hexogen (RDX), hexanitrohexaazaisowurtzitane (CL20), penthrite (PETN), and mixtures thereof, and b) presenting a grain size distribution with a value for D90 less than 15 m and a value for D50 less than or equal to 5 m; and 7% to 12% of a polymer gum selected from polyurethane-polyester gums, polyurethane-polyether gums, and mixtures thereof, of number average molecular weight greater than 20,000 g/mol and of Mooney viscosity lying in the range 20 to 70 ML (5+4) at 100 C.; and wherein the composite explosive product has a thickness lying in the range 0.4 mm to 5 mm.

For production of a propellant charge powder, especially for medium and large calibers, in a process in which the solid is incorporated together with a liquid in a mixing and drying process into the channels of a granular green material and compacted therein to form a plug, the solid, under otherwise identical process conditions, is set within a setting range of >0-0.5% by weight based on the weight of the granular green material. For more significant lowering of the maximum pressure within an upper temperature range and for more significant raising of the maximum pressure within a lower temperature range of the application temperature range, an increased amount of solid is used. The solid is a substance whose melting point is at least 10 C., especially 20 C., above a maximum use temperature of the propellant charge powder and which is inert toward the granular green material. Since the plug consists virtually exclusively of inert material, a high ballistic stability is achieved.

An encapsulated, particulate energetic composition includes one of explosive particles of a known size, oxidizer particles of a known size, and a mixture of explosive particles and oxidizer particles of known sizes, in which particles of one of the explosive particles, the oxidizer particles, and the mixture of the explosive and the oxidizer particles, are encapsulated by a combustible fuel of a known thickness to enhance the energy output. A method of making the encapsulated, particulate energetic composition includes placing one of explosive particles, oxidizer particles, and a mixture of explosive particles and oxidizer particles within a deposition chamber, mixing one of the explosive particles, the oxidizer particles, and the mixture of explosive particles and the oxidizer particles, and depositing, to a known encapsulating thickness, a combustible fuel onto the one of the explosive particles, the oxidizer particles, and the mixture of explosive particles and oxidizer.