Novel Activated Metal Powders for Improved Hybrid Fuels and Green Solid Propellants

The necessity of novel and specialized ingredients for peculiar applications like green solid propellants and fast hybrid fuels is boosting the research of energetic materials to replace conventional metals. Several techniques, such as the Electric Explosion of Wires, have been introduced in past years to find credible replacements for standard micron-sized aluminum. However, several problems related to safety, cost, and actual or potential environmental impact hindered the application of these new materials. In this respect, mechanical and mechanochemical activation processes represent a viable solution to potentially obtain customized ad hoc highly reactive particles. This work deals with the design, production, and characterization of novel mechanically activated ingredients for green solid propellants based on ammonium nitrate and fast-burning hybrid fuels. The activated powders, produced by an innovative technique currently under patenting, are characterized "as is" and their effects on solid propellant and hybrid fuel combustion are evaluated. The novel powders enhance the regression rate of hybrid fuels and reduce the size of the condensed combustion products of green solid propellants based on ammonium nitrate.