Synthesis and characterization of flexible, free-standing, energetic thin films

•Successful synthesized flexible free standing energetic films•Films blade cast using Al + MoO3, KClO4, silicone binder, and xylene.•Flame speeds increased as KClO4 concentration increased.•Flame speeds decreased with the inclusion of reinforcement fabric.•Strength increases dramatically for films reinforced with carbon fiber fabric.

This study uses blade casting methods for the synthesis of flexible, free-standing energetic films. Specifically, films include aluminum (Al) and (MoO3) powder thermites combined with potassium perchlorate (KClO4) and silicone binder. In addition to this base composite, carbon fiber fabric reinforcement fabric has been incorporated to improve the structural integrity of the film. All films were cast at 1 mm thickness with constant percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was recorded with a high speed camera. The results show that the energy propagation of the films increases with increasing mass percent KClO4. The inclusion of carbon fiber fabric reinforcement fabric in the energetic film decreased the flame speed by 30% but maintained stable and steady energy propagation. The strengths of the films were tested to determine the effects of the carbon fiber fabric reinforcement fabric on the mechanical properties of the films. The non-reinforced film, failed upon initial loading of approximately 2.27 kg while the reinforced film maintained a load of 72.3 kg. While this method of synthesis allows manufacture of a flexible free-standing energetic film, the composition and rheology of the mixed slurry have potential as an extrusion cast energetic for additive manufacturing of energetic materials.