Additive Manufacturing of a Special-Shaped Energetic Grain and Its Performance

Area of Science:

• Materials Science
• Chemical Engineering
• Additive Manufacturing

Background:

• Traditional methods for producing special-shaped energetic grains are complex, costly, and pose safety risks.
• There is a need for advanced manufacturing techniques to overcome these limitations.

Purpose of the Study:

• To explore the feasibility of using light-curing 3D printing for fabricating complex special-shaped energetic grains.
• To develop a photocurable resin and energetic slurry for 3D printing energetic materials.

Main Methods:

• Developed a photocurable resin suitable for energetic slurries.
• Formulated a slurry containing ultra-fine ammonium perchlorate (AP), modified aluminum (Al), and photocurable resin.
• Utilized light-curing 3D printing technology to fabricate the energetic grains.
• Characterized the microstructure, density, thermal decomposition, combustion performance, and mechanical properties of the printed grains.

Main Results:

• Successfully 3D printed complex special-shaped energetic grains with smooth surfaces and dense internal structures.
• Achieved an average density of 1.606 g·cm⁻³ with good uniformity and stability.
• Observed a three-stage thermal decomposition process, with aluminum catalyzing ammonium perchlorate decomposition.
• Demonstrated a consistent burning rate of 5.11 mm·s⁻¹ with uniform flame and one-way jet.
• Recorded a peak pressure of 45.917 KPa and a pressurization rate of 94.874 KPa·s⁻¹.
• Obtained compressive strength of 9.83 MPa and tensile strength of 8.78 MPa.

Conclusions:

• Light-curing 3D printing is a feasible and effective method for manufacturing complex special-shaped energetic grains.
• The developed energetic slurry and printing process yield materials with desirable properties for energetic applications.
• This additive manufacturing approach offers enhanced safety, adaptability, and potentially lower costs compared to conventional methods.