Ignition and combustion behavior of mechanically activated Al-Mg particles in composite solid propellants

Metallized propellants typically produce large agglomerates that result in two-phase flow losses. Tailoring composite metal fuel particles can improve ignition and combustion characteristics while reducing product droplet sizes. In this work, mechanically activated (MA) aluminum (Al) and magnesium (Mg) powders are synthesized, characterized and compared to magnalium (Mag) alloy, neat Al, neat Mg and their physical mixtures (PM) at the same 1:1 mass ratio as MA and Mag powders. CO2 laser ignition tests showed that the MA powders are more reactive than those of Mag and exhibit particle fragmentation upon ignition. Mag powders only show fragmentation and microexplosions at high heating rates. The burning rates of the ammonium perchlorate/hydroxyl-terminated polybutadiene composite propellants containing MA powders were the highest, compared to Mag, neat Al, PM and neat Mg in decreasing order. High-speed imaging of the propellants and product collection showed that MA, Mg and Mag powders produce much smaller agglomerates than neat Al or PM at lower pressures due to fragmentation and Mg vaporization. However, the microexplosion tendency of the MA and Mag particles in the propellants was reduced at higher pressures due to reduced vapor bubble growth. Out of all the materials investigated, MA particles provide the best combination of burning rate and product sizes.