A method for gas atomization of oxygen-reactive reactive metals and alloys wherein the atomized particles are exposed as they solidify and cool in a very short time to multiple gaseous reactive agents for the in-situ formation of a protective reaction film on the atomized particles. The present invention is especially useful for making highly pyrophoric reactive metal or alloy atomized powders, such as atomized magnesium and magnesium alloy powders. The gaseous reactive species (agents) are introduced into the atomization spray chamber at locations downstream of a gas atomizing nozzle as determined by the desired powder or particle temperature for the reactions and the desired thickness of the reaction film.

A multi-compartment microcapsule produces heat when subjected to a stimulus (e.g., a compressive force, a magnetic field, or combinations thereof). In some embodiments, the multi-compartment microcapsules have first and second compartments separated by an isolating structure adapted to rupture in response to the stimulus, wherein the first and second compartments contain reactants that come in contact and react to produce heat when the isolating structure ruptures. In some embodiments, the multi-compartment microcapsules are shell-in-shell microcapsules each having an inner shell contained within an outer shell, wherein the inner shell defines the isolating structure and the outer shell does not allow the heat-generating chemistry to escape the microcapsule upon rupture of the inner shell.

A solid rocket propellant grain having rocket propellant and a membrane in contact with the rocket propellant. The membrane includes a highly heat conductive pattern which affects the propellant burning rate through localized conductive heat transfer from the combustion zone and into the uncombusted propellant. Different geometries for the thermally conductive pattern produce different combustion results.

The present invention is directed to an explosive composition comprised of heavy ANFO and expanded polymeric beads that have a density that is less than the density of the heavy ANFO. The expanded polymeric beads have a size that is determined or based on the size of ammonium nitrate prills used in the heavy ANFO portion of the composition. In one embodiment, the expanded polymeric beads that are utilized in the composition are at least 70% of the lower limit of the mesh size of the predominant ammonium nitrate prill mesh size. In another embodiment, the expanded polymeric beads are at least 70% of a size that is related to the average mesh size of the ammonium nitrate prills.

The present invention is directed to an explosive composition comprised of heavy ANFO and expanded polymeric beads that have a density that is less than the density of the heavy ANFO. The expanded polymeric beads have a size that is determined or based on the size of ammonium nitrate prills used in the heavy ANFO portion of the composition. In one embodiment, the expanded polymeric beads that are utilized in the composition are at least 70% of the lower limit of the mesh size of the predominant ammonium nitrate prill mesh size. In another embodiment, the expanded polymeric beads are at least 70% of a size that is related to the average mesh size of the ammonium nitrate prills.

Compositions, devices, and methods for destroying chemical warfare agents, independent of their chemical make-up, include (i) at least one reactive metal; (ii) at least one oxidizer; and (iii) a binder. In one embodiment, the self-sustaining reactive composition includes magnesium powder, iron oxide powder, potassium perchlorate powder, and silicone gel. In another embodiment, the self-sustaining reactive composition includes manganese powder, lithium perchlorate powder, lithium peroxide powder, and silicone gel. The reactive metal(s), oxidizer(s), binder, and their respective amounts, are selected such that, following ignition of the composition, the composition is capable of producing a solid mass of ash (wicking composition) that increases the surface area of the chemical agent material and provides a site for combustion and/or thermal degradation of the chemical agent to occur.

Compositions, devices, and methods for destroying chemical warfare agents, independent of their chemical make-up, include (i) at least one reactive metal; (ii) at least one oxidizer; and (iii) a binder. In one embodiment, the self-sustaining reactive composition includes magnesium powder, iron oxide powder, potassium perchlorate powder, and silicone gel. In another embodiment, the self-sustaining reactive composition includes manganese powder, lithium perchlorate powder, lithium peroxide powder, and silicone gel. The reactive metal(s), oxidizer(s), binder, and their respective amounts, are selected such that, following ignition of the composition, the composition is capable of producing a solid mass of ash (wicking composition) that increases the surface area of the chemical agent material and provides a site for combustion and/or thermal degradation of the chemical agent to occur.

A hybrid rocket solid fuel grain having a cylindrical shape and defining a center port is additive manufactured from a compound of thermoplastic fuel and passivated nanocomposite aluminum additive. The fuel grain comprises a stack of fused layers, each formed as a plurality of fused abutting concentric circular beaded structures of different radii arrayed defining a center port. During operation, an oxidizer is introduced along the center port, with combustion occurring along the exposed port wall. Each circular beaded structure possesses geometry that increases the surface area available for combustion. As each layer ablates the next abutting layer, exhibiting a similar geometry is revealed, undergoes a gas phase change, and ablates. This process repeats and persists until oxidizer flow is terminated or the fuel grain material is exhausted. To safety achieve this construction, a fused deposition additive manufacturing apparatus, modified to shield the nanocomposite material from the atmosphere is used.

The present invention relates to the field of coatings on high-energy materials, devices or products that comprise the coated high-energy materials, functional coating materials and methods for producing and using the same. In particular, the present invention relates to energetic materials having initiated release coatings to improve the performance and shelf-life of the devices, products and/or raw materials, suitable for use as energetics or propellants for munitions, rockets, pyrotechnics, flares or other devices or components.

The invention provides mechanically activated metal fuels for energetic material applications. An exemplary embodiment involves mechanically treating micrometer-sized particles of at least one metal with particles of at least one fluorocarbon to form composite particles containing the at least one metal and the at least one fluorocarbon.