Controllable preparation of hexanitrostilbene (HNS) microspheres with multi-cavity structure to enhance safety and combustion performance

Controlling the structure to meet the demand for high-energy, low-sensitivity energetic materials in modern military and civilian applications is an effective method. In this study, hexanitrostilbene (HNS) microspheres with a multi-cavity structure were prepared using nitrocellulose (NC) and fluororubber (F₂₆₀₄) as binders via microjet droplet technology. The effects of flow rate, receiving liquid temperature, and suspension concentration on the morphology, particle size, and cavity of the HNS microspheres were investigated. Furthermore, the impact of the multi-cavity structure on the microspheres' specific surface area, dispersibility, thermal properties, safety performance, and combustion performance was studied. Results showed that the multi-cavity HNS microspheres retained the raw materials' crystal structure while exhibiting improved dispersibility, higher activation energy, and shorter ignition delay. Moreover, the multi-cavity structure outperformed the solid structure in terms of specific surface area, safety performance, and combustion performance. This study opens up a new direction for the preparation of multi-structured energetic microspheres.