The structural integrity and combustion safety of composite solid propellants under extreme service environments remain critical concerns. In this study, a typical HTPB/AP/Al composite propellant was subjected to 56-day cryo-thermal cycling to investigate the effects on microstructure, thermal decomposition, and combustion behavior. Scanning electron microscopy revealed progressive interfacial debonding, pore coalescence, and AP crystal fracture induced by repeated cryo-thermal cycles. Thermogravimetry-differential scanning calorimetry indicated that the main decomposition stage exhibited intensified heat release, increased mass loss rates, and a shift of the AP high-temperature decomposition peak toward higher values. Combustion tests demonstrated that the burning rate and pressure exponent increased with the severity of cryo-thermal cycling, particularly under long-term exposure. At 1.6 MPa, cycled samples displayed brighter, smokier, and more unstable flames. The findings support the life prediction and combustion safety optimization of propellants in extreme environments.
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