Novel Approach for the Fabrication of Composite Rocket Propellant: Increased Homogeneity and Its Influence on SRP Behaviour.

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Title: Novel Approach for the Fabrication of Composite Rocket Propellant: Increased Homogeneity and Its Influence on SRP Behaviour.
Authors: Janowska, Kinga1 (AUTHOR), Procek, Marcin2 (AUTHOR), Warski, Tymon3 (AUTHOR), Polis, Mateusz4,5 (AUTHOR), Stolarczyk, Agnieszka1,5 (AUTHOR) agnieszka.stolarczyk@polsl.pl, Hawelek, Lukasz1,3 (AUTHOR)
Source: Materials (1996-1944). Mar2026, Vol. 19 Issue 5, p979. 18p.
Subjects: Electrostatic atomization, Solid propellants, Thermolysis, Energy dispersive X-ray spectroscopy, Friction measurements, Porosity, Scanning electron microscopy
Abstract: In this study, the feasibility of electrospraying as an alternative processing technique for the preparation of composite solid rocket propellants (SRPs) was investigated. The main objective was to improve microstructural homogeneity and interfacial contact between the oxidizer, energetic additive, and metallic fuel without altering the chemical composition of the formulation. Additionally, porous electrosprayed SRP formulations were prepared to examine the influence of controlled porosity on thermal decomposition behavior. The prepared materials were characterized using scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM/EDS) to assess microstructural features and component distribution. Thermal decomposition behavior and kinetic parameters were evaluated using simultaneous DSC/TG analysis conducted at multiple heating rates. Safety-related properties were assessed through friction sensitivity testing, while post-decomposition solid residues were analyzed using SEM/EDS and X-ray diffraction. The results show that electrospraying improves structural homogeneity, reduces solid residue formation after thermal decomposition, and decreases apparent activation energy, while maintaining unchanged friction sensitivity. These findings demonstrate the potential of electrospraying as a physical processing route for tailoring the microstructure and thermal behavior of composite solid rocket propellants. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Novel Approach for the Fabrication of Composite Rocket Propellant: Increased Homogeneity and Its Influence on SRP Behaviour.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Mar2026, Vol. 19 Issue 5, p979. 18p.
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  Data: <searchLink fieldCode="DE" term="%22Electrostatic+atomization%22">Electrostatic atomization</searchLink><br /><searchLink fieldCode="DE" term="%22Solid+propellants%22">Solid propellants</searchLink><br /><searchLink fieldCode="DE" term="%22Thermolysis%22">Thermolysis</searchLink><br /><searchLink fieldCode="DE" term="%22Energy+dispersive+X-ray+spectroscopy%22">Energy dispersive X-ray spectroscopy</searchLink><br /><searchLink fieldCode="DE" term="%22Friction+measurements%22">Friction measurements</searchLink><br /><searchLink fieldCode="DE" term="%22Porosity%22">Porosity</searchLink><br /><searchLink fieldCode="DE" term="%22Scanning+electron+microscopy%22">Scanning electron microscopy</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: In this study, the feasibility of electrospraying as an alternative processing technique for the preparation of composite solid rocket propellants (SRPs) was investigated. The main objective was to improve microstructural homogeneity and interfacial contact between the oxidizer, energetic additive, and metallic fuel without altering the chemical composition of the formulation. Additionally, porous electrosprayed SRP formulations were prepared to examine the influence of controlled porosity on thermal decomposition behavior. The prepared materials were characterized using scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM/EDS) to assess microstructural features and component distribution. Thermal decomposition behavior and kinetic parameters were evaluated using simultaneous DSC/TG analysis conducted at multiple heating rates. Safety-related properties were assessed through friction sensitivity testing, while post-decomposition solid residues were analyzed using SEM/EDS and X-ray diffraction. The results show that electrospraying improves structural homogeneity, reduces solid residue formation after thermal decomposition, and decreases apparent activation energy, while maintaining unchanged friction sensitivity. These findings demonstrate the potential of electrospraying as a physical processing route for tailoring the microstructure and thermal behavior of composite solid rocket propellants. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19050979
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      – Code: eng
        Text: English
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        StartPage: 979
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      – SubjectFull: Electrostatic atomization
        Type: general
      – SubjectFull: Solid propellants
        Type: general
      – SubjectFull: Thermolysis
        Type: general
      – SubjectFull: Energy dispersive X-ray spectroscopy
        Type: general
      – SubjectFull: Friction measurements
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      – SubjectFull: Porosity
        Type: general
      – SubjectFull: Scanning electron microscopy
        Type: general
    Titles:
      – TitleFull: Novel Approach for the Fabrication of Composite Rocket Propellant: Increased Homogeneity and Its Influence on SRP Behaviour.
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            NameFull: Janowska, Kinga
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            NameFull: Procek, Marcin
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            NameFull: Polis, Mateusz
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            – D: 01
              M: 03
              Text: Mar2026
              Type: published
              Y: 2026
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