On‐demand microwave growth of porosity within a granular composite energetic material: Void formation via a dielectric loss phase change binder additive for propellant burning rate control

This study demonstrates, for the first time ever, the ability to grow, in an on‐command fashion, porosity within a granular composite energetic material to effect a change in energy output rate. Specifically, the study investigates the change in burning rates of ammonium perchlorate composite propellants as a result of porosity created in situ via microwave field‐driven volatilization of the low boiling point binder additive, ethylene glycol. Theoretical mass densities were measured before and after microwave irradiation finding that the maximum observed %TMD change for tested propellants is 6 %. Propellants were burned at 1.72 MPa to 6.89 MPa pressures, finding that for all propellants, microwave irradiation produced a change in ballistic characteristics. Most propellant formulations demonstrate acceptable burning rate parameters for use within rocket motors; some exhibited a large change in their pressure exponent as well as slope breaks attributed to the onset of convective burning, while microwave irradiation produced no change in burning rate or density in reference propellants without the additive. Microwave heating simulation results are presented to gain insight into the thermal environment of the propellant during microwave irradiation. These results provide valuable insight into propellant formulations that can have their burning rates (and thus the thrust profile for motor grains) altered after casting via microwave irradiation.