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An alarming, asymmetric flame in rocket combustion originates from a composite solid propellant (CSP) containing defects. The defects are the result of a composition that exceeds the maximum particle packing density. Based on the structure analysis of CSP, the addition of plasticizer causes the correlation between the viscosity of CSP slurry and particle packing density to become uncertain. This work aims to investigate the influence of thixotropic behavior on the maximum particle packing density of CSP. A CSP with different thixotropic behavior was successfully produced using aluminum/plasticizer dioctyl adipate (DOA) of 12–24. During the curing process, viscosity and stress–growth were investigated. The structure of the CSP was defined using X-ray radiography. It is remarkably observed that the peak of thixotropy occurred at the 15th minute of the curing process. The particle packing density of CSP can be decisive for the relative viscosity at the peak time of thixotropic behavior. The CSP with the highest relative viscosity at the peak time was revealed to have voids in the upper part of the CSP. Thus, this parameter was proven to change the preceding parameter, viscosity that was measured at the end of mixing. Based on the stress–growth analysis, it is conceivable that the mechanism involves the time-dependent diffusion of DOA in weakening aluminum agglomerates.

The kinetics of hexogen coating with polyurethane-based hydroxyl-terminated polybutadiene (HTPB) using infrared spectrometry was investigated. The kinetics model was evaluated through reaction steps: (1) hydroxyl and isocyanate to produce urethane, (2) urethane and isocyanate to produce allophanate, and (3) nitro and isocyanate to produce diazene oxide and carbon dioxide. HTPB, ethyl acetate, TDI (toluene diisocyanate), and hexogen were mixed for 60 min at 40 °C. The sample was withdrawn and analyzed with infrared spectroscopy every ten minutes at reference wavelengths of 2270 (the specific absorption for isocyanate groups) and 1768 cm−1 (the specific absorption for N=N groups). The solvent was vaporized; then, the coated hexogen was cured in the oven for 7 days at 60 °C. The effect of temperature on the coating kinetics was studied by adjusting the reaction temperature at 40, 50, and 60 °C. This procedure was repeated with IPDI (isophorone diisocyanate) as a curing agent. The reaction rate constant, k3, was calculated from an independent graphic based on increasing diazene oxide concentration every ten minutes. The reaction rate constants, k1 and k2, were numerically calculated using the Newton–Raphson and Runge–Kutta methods based on decreasing isocyanate concentrations. The activation energy of those steps was 1178, 1021, and 912 kJ mole−1. The reaction rate of hexogen coating with IPDI was slightly faster than with TDI.

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