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

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.