A systematic overview of melt cast explosives is given. The research on melt cast explosives over several decades can be divided into three broad areas: (i) aromatic compounds with CCH3, NCH3, OCH3 CNO2, NNO2 and ONO2 groups, (ii) improved synthesis of compounds, which are currently used in formulations or which have shown promise for such use and (iii) the preparation of melt cast formulations with various compositions. Exudation, high volume change from liquid to solid, super cooling, irreversible growth, fragility and unpredictable sensitivity are the disadvantages of existing melt cast formulations.

This paper reviews the research and development work on CL-20, the most powerful high-energy material of today, as well as CL-20-based formulations. Methods of CL-20 synthesis and processes for obtaining a desired particle size are discussed. Particular attention is paid to optimization of conditions for obtaining the most stable high-density polymorph. The Fourier Transform Infrared spectroscopy and X-ray diffraction appear to be effective means for distinguishing CL-20 polymorphs. The thermal decomposition pattern of CL-20 as well as the proposed decomposition and combustion mechanisms also form part of this manuscript. Investigations performed by various researchers show that its relatively high sensitivity needs special attention from the viewpoint of CL-20 preparation and processing of formulations based on this substance. Salient features of CL-20-based explosives and gun/rocket propellants studied are included into this review. CL-20 may be ranked as the most attractive compound for futuristic explosive and propellant formulations. The research activities performed by the authors on synthesis and characterization of CL-20 are briefly described.

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