Design of Litchi-Like Al/PTFE with Superior Reactivity and Application in Solid Propellants

The combustion efficiency and reactivity of aluminum (Al) particles, as a crucial component in solid propellants, are constrained by the inert oxide layer aluminum oxide (Al₂O₃). Polytetrafluoroethylene (PTFE) can remove the oxide layer, however, carbon deposition generated during the reaction process still limits the reaction efficiency of Al/PTFE fuel. Here, a litchi-like Al/PTFE fuel with the nano-PTFE islands distributed on the Al particles surface is successfully designed, based on localized activation and synergistic reaction strategies, to solve the Al₂O₃ layer and carbon deposition. This unique PTFE-coated structure can achieve localized activation of Al by surface etching, creating reaction channels, and exposing the active Al. Such a channel network promotes the circulation of fluorine and oxygen, stimulating the synergistic reactions of Al-F and Al-O and energy output. Regulating the PTFE content can maximize the elimination of carbon deposition and achieve the full combustion reaction of Al/PTFE. The maximum flame area and pressure output of the litchi-like Al/PTFE fuel increased by 241.9%, 734.7%, 118.4%, and 265.2%, respectively, compared with traditional physical mixture and core-shell structure Al/PTFE fuels. The localized activation and synergistic effects of litchi-like structure effectively transform carbon waste into a valuable resource, introducing a novel approach for the propellants.