A method for the manufacture of stable amorphous secondary explosives and combinations thereof—wherein the stability is enhanced with the addition of a polymeric additives and can be further enhanced with mechanical compression of the amorphous material.

A method of manufacturing a CL-20/HMX cocrystalline explosive which is coated in a polymeric binder, so as to be useful as an explosive molding powder. The cocrystalline material having a desirable average crystal size of from about 300 nm to about 1000 nm, which crystals are intimately coated with a polymeric binder and are produced as granular agglomerates that are less than on average 5 microns in size, and which crystals are relatively easy and safe to handle, transport, store and use. The method involving spray drying a CL-20 and HMX solvent solution containing a polymeric binder to form an intermediary amorphous material—which intermediary is then heated to cocrystallize the CL-20/HMX into the desired size cocrystals and aggregates thereof—which are coated in said polymeric binder.

A combustible solid propellant composition is disclosed that includes an oxidizer of the reaction product under vacuum of potassium periodate and isocyanate, a polymer binder, a plasticizer, and a fuel.

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.

The present invention relates to methods of preparing pre-mixed compositions that can be combined to form pyrotechnic compositions. In exemplary embodiments, a binder ingredient is premixed with the pyrotechnic fuels and can also include other pyrotechnic additives and processing aides. Other binder ingredients can be premixed with the pyrotechnic oxidizers and can also include other pyrotechnic additives and processing aides. The resulting mixtures are not explosive and are therefore easier to store and much safer to handle. These pre-mixed mixtures can be stored in bulk until needed and rapidly combined to achieve final composition.

The present invention relates to methods and processes to prepare pre-mixed compositions that can be combined to form pyrotechnic compositions in mixed multiple parts. In exemplary embodiments, a binder curing agent ingredient is premixed with pyrotechnic fuels and can also include other pyrotechnic additives and processing aides. Other binder ingredients such as a binder resin can be premixed with the pyrotechnic oxidizers and can also include other pyrotechnic additives and processing aides. The resulting mixtures are not explosive and are much safer to handle and easier to store for extended shelf-life over a final pyrotechnic composition. Further, the pre-mixed mixtures can be stored in bulk until needed and rapidly combined to achieve the final pyrotechnic composition.

The invention relates to a cast explosive composition, particularly to a pre-cure castable explosive composition comprising an explosive material, a polymerisable binder, a microencapsulated cross linking reagent, said microencapsulated cross linking reagent, comprising a cross linking agent encapsulated in a microcapsule. Providing a process for formulating a homogenous crosslinked polymer bonded explosive composition comprising the steps of: i) forming an admixture of pre-cure castable explosive composition, said composition comprising an explosive material, a polymerisable binder, a microencapsulated cross linking reagent, said microencapsulated cross linking reagent, comprising a cross linking reagent encapsulated in a microcapsule;
wherein the microcapsule, comprises at least one shell wall polymer, wherein the microcapsule's shell wall polymer comprises at least one resonant acoustic stimulus labile linkage, ii) applying resonant acoustic stimulus to the admixture, causing the microcapsule to rupture and release said cross linking reagent, to cause the cure process to start.

The invention relates to a cast explosive composition. A process for formulating a homogenous crosslinked polymer bonded explosive composition comprising the steps of: i) forming an admixture of precure castable explosive composition, comprising an explosive material, a polymerisable binder, and a cross linking reagent which comprises at least two reactive groups each of which is protected by a labile blocking group, wherein the labile blocking groups, comprise at least one resonant acoustic mixing stimulus labile linkage, ii) applying resonant acoustic mixing stimulus to the admixture, causing the at least one resonant acoustic mixing stimulus labile linkage to be removed and release said cross linking reagent, to cause the cure process to start. ##STR00001##

The invention is directed to a radiation curable energetic composition, to a method of forming a three-dimensional energetic object, to a three-dimensional energetic object, and to uses of the radiation curable energetic composition.

The radiation curable energetic composition of the invention comprises

(a) one or more polymerisable components,
(b) one or more polymerisation initiators, and
(c) one or more energetic components.

The present invention comprises formulations and method for additive manufacturing comprising: a pot-stable photo-curable polymer; one or more fillers; and one or more additives, wherein the formulation cures into a polymer in six hours or less upon exposure to light. In certain examples, the additive manufacturing is a moldless method of additive manufacturing by preparing a formulation comprising: a pot-stable photo-curable polymer, one or more fillers, and one or more additives, and exposing the formulation to light in an amount that substantially cures the polymer in 6 hours or less.