High-speed
air-breathing propulsion systems, such as solid fuel
ramjets (SFRJ), are important for space exploration and national security.
The development of SFRJ requires high-performance solid fuels with
excellent mechanical and combustion properties. One of the current
solid fuel candidates is composed of high-energy particles (e.g.,
boron (B)) and polymeric binder (e.g., hydroxyl-terminated polybutadiene
(HTPB)). However, the opposite polarities of the boron surface and
HTPB lead to poor B particle dispersion and distribution within HTPB.
Herein, we demonstrate that the surface functionalization of B particles
with nonpolar oleoyl chloride greatly improves the dispersion and
distribution of B particles within HTPB. The improved particle dispersion
is quantitatively visualized through X-ray computed tomography imaging,
and the particle/matrix interaction is evaluated by dynamic mechanical
analysis. The surface-functionalized B particles can be uniformly
dispersed up to 40 wt % in HTPB, the highest mass loading reported
to date. The surface-functionalized B (40 wt %)/HTPB composite exhibits
a 63.3% higher Young’s modulus, 87.5% higher tensile strength,
16.2% higher toughness, and 16.8% higher heat of combustion than pristine
B (40 wt %)/HTPB. The surface functionalization of B particles provides
an effective strategy for improving the efficacy and safety of B/HTPB
solid fuels for future high-speed air-breathing vehicles.