Aluminum agglomeration involving the second mergence of agglomerates on the solid propellants burning surface: Experiments and modeling

The agglomeration of aluminum particles usually occurs on the burning surface of aluminized composite propellants. It leads to low propellant combustion efficiency and high two-phase flow losses. To reach a thorough understanding of aluminum agglomeration behaviors, agglomeration processes, and particles size distribution of Al/AP/RDX/GAP propellants were studied by using a cinephotomicrography experimental technique, under 5 MPa. Accumulation, aggregation, and agglomeration phenomena of aluminum particles have been inspected, as well as the flame asymmetry of burning agglomerates. Results reveals that the dependency of the mean and the maximum agglomeration diameter to the burning rate and the virgin aluminum size have the same trend. A second-time mergence of multiple agglomerates on the burning surface is unveiled. Two typical modes of second mergence are concluded, based upon vertical and level movement of agglomerates, respectively. The latter mode is found to be dominant and sometimes a combination of the two modes may occur. A new model of aluminum agglomeration on the burning surface of composite propellants is derived to predict the particulates size distribution with a low computational amount. The basic idea is inspired from the well-known pocket models. The pocket size of the region formed by adjacent AP particles is obtained through scanning electron microscopy of the propellant cross-section coupled to an image processing method. The second mergence mechanism, as well as the effect of the burning rate on the agglomeration processes, are included in the present model. The mergence of two agglomerates is prescribed to occur only if their separation distance is less than a critical value. The agglomerates size distribution resulting from this original model match reasonably with the experimental data. Moreover, the present model gives superior results for mean agglomeration diameter compared to common empirical and pocket models. The average prediction error is lower than 5% for the four propellants tested. Results of this study are expected to provide better insight and enrich in the theoretical frame of aluminum agglomeration.