A new, rapid and inexpensive synthesis method for monodispersed triaminotrinitrobenzene (TATB) microparticles based on micelle-confined precipitation that enables control of microscopic morphology. The morphology of the TATB microparticles can be tuned between quasi-spherical and faceted by controlling the speed of recrystallization. The method enables improved performance and production consistency of TATB explosives for military grade explosives and propellants

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.

A surfactant-assisted self-assembly method can be used to crystallize energetic materials with controlled morphology. Microparticles of hexanitrohexaazaisowurtzitane (CL-20) formed by this method may have enhanced functional reproducibility due to their monodisperse nature, and decreased shock sensitivity due to their sub-2 m particle size.

A system and method for producing fuel grain for a rocket engine horizontally with an additive manufacturing machine is disclosed. To begin, a fuel grain model is received. The fuel grain model is oriented in a direction of a central core axis and divided into two-dimensional layers with defined footprint areas. In accordance with the fuel grain model, a first layer is printed by applying successive fuel beads in a direction primarily parallel to the central core axis.

A system is used for additively manufacturing propellant elements, such as for rocket motors, includes partially curing a propellant mixture before extruding or otherwise dispensing the material, such that the extruded propellant material is deposited on the element in a partially-cured state. The curing process for the partially-cured extruded material may be completed shortly after the material is put into place, for example by the material being heated at or above its cure temperature, such that it finishes curing before it fully cools. The propellant material may be prepared by first mixing together, a fuel, an oxidizer, and a binder, such as in an acoustic mixer. After that mixing a curative may be added to the mixture. The propellant mixture may then be directed to an extruder (or other dispenser), in which the mixture is heated to or above a cure temperature prior to the deposition, and then deposited.

Disclosed herein are electrically operated propellants and methods of making and use thereof. The electrically operated propellants comprise a thermoplastic ionomer and a carbonaceous material. The electrically operated propellants are air stable and are configured to ignite at an ignition condition, wherein the ignition condition is that a physical defect is introduced and an electrical input is applied after the introduction of the physical defect, to thereby ignite the electrically operated propellant.

The present invention relates to a manufactured graphene/metal or metalloid core-shell composite and manufacturing method thereof. The method comprising: using a modified graphene oxide as a base, then performing concentration and steam drying followed by organic solvent replacement to obtain a modified graphene oxide organic solvent; using a liquid-phase self-assembly method to coat the modified graphene oxide onto a surface of the metal or metalloid to form a graphene/metal or metalloid coated particle solution, then filtering and drying to obtain the graphene metal/metalloid core-shell composite. The method improves upon a conventional organic and inorganic material coating technique, and reduces an impact of a water-based solvent and high temperature on a highly reactive metal and metalloid, thereby expanding the feasibility of the coating technique and addressing a barrier of applicability of graphene and reactive metal or metalloid in the field of energetic materials.

A method of additively manufacturing propellant elements, such as for rocket motors, includes partially curing a propellant mixture before extruding or otherwise dispensing the material, such that the extruded propellant material is deposited on the element in a partially-cured state. The curing process for the partially-cured extruded material may be completed shortly after the material is put into place, for example by the material being heated at or above its cure temperature, such that it finishes curing before it fully cools. The propellant material may be prepared by first mixing together, a fuel, an oxidizer, and a binder, such as in an acoustic mixer. After that mixing a curative may be added to the mixture. The propellant mixture may then be directed to an extruder (or other dispenser), in which the mixture is heated to or above a cure temperature prior to the deposition, and then deposited.

A new, rapid and inexpensive synthesis method for monodispersed triaminotrinitrobenzene (TATB) microparticles based on micelle-confined precipitation that enables control of microscopic morphology. The morphology of the TATB microparticles can be tuned between quasi-spherical and faceted by controlling the speed of recrystallization. The method enables improved performance and production consistency of TATB explosives for military grade explosives and propellants

A surfactant-assisted self-assembly method can be used to crystallize energetic materials with controlled morphology. Microparticles of hexanitrohexaazaisowurtzitane (CL-20) formed by this method may have enhanced functional reproducibility due to their monodisperse nature, and decreased shock sensitivity due to their sub-2 m particle size.