The combustion efficiency of Al plays a critical role
in the combustion
of high-energy aluminum-based solid propellants. For traditional formulations,
the Al powders are dispersed in the binder matrix, leading to limited
contact with the oxidizers and hence usually insufficient combustion
and higher values of the pressure exponent. In this paper, various
core–shell structural Al/oxidizer composites such as Al@HMX,
Al@AP, and AP@Al have been prepared by a spray-drying technique based
on which solid propellants with precise interfacial control between
Al particles and oxidizers were realized. Compared to the control
sample, the modified propellants have a greater heat of explosion
of 5890 J g–1 (15% higher) and a reduced ignition
delay time of 58 ms (65% decrease). Without changing the content of
components, the burn rates of propellants can be easily modulated
by tuning the interfacial contact of Al and oxidizers, where it varies
in a wide range of 4.56–5.79 mm s–1 at the
same pressure of 1 MPa. After introducing Al/oxidizer composites,
the lowest pressure exponent of 0.19 within 1–15 MPa could
be achieved by using Al@HMX and AP@Al composites. The agglomeration
of Al was also inhibited by using Al/oxidizer composites, and the
mechanism can be interpreted by using a classical “pocket”
model. Moreover, the improved combustion efficiency of the solid propellants
was verified by a noticeable reduction in the unreacted Al content.