The present invention is directed to a process for preparing light curable energetic polymeric binders. The process for preparing such binder comprises the steps of mixing a pre-polymer such as PGN or GAP having a terminal hydroxyl group with a solvent and adding reactants wherein the reactant has a light curable moiety and a pre-polymer reactive moiety. Catalysts such as carbodiimide and DMAP may be further added to the mixture.

The invention is directed to a solid, porous material for generating hydrogen gas, said material having a porosity of 20 to 75 vol %, and a composition comprising, based on the weight of the material, 50 to 99% of a boron hydride compound, and 1 to 30% of a binder. A further aspect of the invention relates to a gas generator comprising said material and use thereof in aerospace applications.

Solid-fuel rocket propellants comprising an oxidizer, an oxophilic metal-halophilic metal formulation, and a binder are described herein. Further described are processes for preparing such propellants and methods of reducing hydrogen chloride production via the combustion of such propellants. Non-limiting examples of such formulations include aluminum-lithium alloys.

A potted electronic device comprises an electronic device at least partially encapsulated by an energetic potting material. The energetic potting material comprises a halogenated urethane binder and a metal fuel dispersed within the halogenated urethane binder. Related energetic potting materials and methods of forming electronic devices at least partially encapsulated with the energetic potting materials are also disclosed.

A composite pyrotechnic product containing energetic charges in a plasticized binder includes a cured energetic polymer and at least one energetic plasticizer, wherein: the cured energetic polymer consists of a glycidyl azide polymer (GAP) having a number average molecular weight (Mn) lying in the range 700 g/mol to 3000 g/mol and cured via its hydroxyl terminal functions with at least one curing agent of polyisocyanate type; and the energetic charges present at a content in the range 50% to 70% by weight consisting, for at least 95% of their weight, of large crystals of ammonium dinitramide (ADN) and of small crystals of hexogen (RDX): the large crystals of ammonium dinitramide (ADN) being present at a content in the range 8% to 65% by weight; and the small crystals of hexogen (RDX) being present at a content in the range 5% to 55% by weight.

A method for non-destructively determining a mechanical property of a solid rocket motor propellant grain may comprise applying a force to a surface of the solid rocket motor propellant grain, wherein a deformation is formed on the surface of the solid rocket motor propellant grain in response to the applying, and calculating a value of the mechanical property of the solid rocket motor propellant grain based on the deformation. This process may be performed over time to determine a lifespan of the propellant grain.

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.

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.

The present invention relates to a composition for single-base propelling powder for ammunition consisting of nitrocellulose as an explosive base, an inert plasticizer component, at least one nitrocellulose stabilizer component, and optionally a flash-reducer component and traces of one or more solvents and water. The aforementioned inert plasticizing component is dibutyl sebacate (DBS). Preferably, the dibutyl sebacate is present with a content between 2% and 7% by weight.

A method of forming polymer composites includes mixing a transition metal oxide precursor including at least one transition metal, a polymer as a binder, a solvent for the polymer, and water to form a first solution including polymer-transition metal complexes. The polymer-transition metal complexes are hydrolyzed to produce a plurality of transition metal oxide nanoparticles, wherein water is added in the mixing in a stoichiometric excess for the hydrolyzing. The solvent and residual of the water remaining after the hydrolyzing are removed. A polymer composite including the transition metal oxide nanoparticles dispersed in the polymer results after the removing, where some of the polymer is chemically conjugated to a surface of the transition metal oxide nanoparticles.