Following a detailed literature survey on the fracture-mechanics properties of solid rocket propellants, this paper reports on an innovative set of fracture tests performed on a composite solid propellant based on ammonium perchlorate hydroxyl-terminated polybutadiene. After a short summary on standard linear–viscoelastic mechanical characterization, results on both linear–elastic fracture-mechanics (characterized by the fracture toughness KIC) and nonlinear fracture-mechanics (characterized by GF) tests are reported. Test results for linear–elastic fracturemechanics simulations have been obtained using middle-tension specimens. A practical methodology to separate the\ud amount of strain energy lost through viscous processes from other sources is given and provides an effective method to apply the toughness-test validity criteria of the American Society for Testing and Materials E399 norm to propellants and other thermoviscoelastic materials. Measurements to determine the linear fracture-mechanics properties of the propellant have been carried out applying the wedge-splitting test methodology. Master curves for the toughness, the critical crack-opening displacement, and the fracture energy have been generated to correlate test\ud data. Results are coherent with Shapery’s theory of fracture for viscoelastic materials. Results can be used within finite element simulations to assess the safety and integrity of a solid-propellant rocket motor under various loads, such as thermal cycling and ignition, assuming stationary conditions

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Polymer Optical Fibers are proposed for the monitoring of structural health condition of energetic materials in solid rocket motors. This photonic solution provides the necessary electromagnetic immunity and inherent electrical safety characteristics in the highly explosive environment of SRM's propellant. Furthermore the use of POF's intrinsic elasticity in contrast to silica fibers makes possible the monitoring of excessive strains apparent in the behavior of the energetic propellant. Both jacketed and unjacketed fibers were employed demonstrating excellent strain transfer characteristics able to monitor consistently propellant's behavior under strain.

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