Thermal decomposition and combustion characteristics of Al/AP/HTPB propellant

Aluminum(Al)/ammonium perchlorate(AP)/hydroxyl-terminated polybutadiene (HTPB) propellant is the most widely used propulsion system currently. Its ignition and combustion processes are fairly complex and need to be better understood. In this study, the thermal decomposition, ignition, and combustion properties of an Al/AP/HTPB propellant were investigated using a thermogravimetry–differential scanning calorimetry and a laser ignition testing system. The morphology and size distribution of the condensed combustion products (CCPs) were analyzed using a laser particle size analyzer and scanning electron microscopy. Results showed that the thermal decomposition process of the propellant consisted of three stages. The first stage (100–430 °C) was a major mass loss stage and exhibited typical features of AP decomposition. The second stage (430–630 °C) was mainly accompanied by the decomposition of remaining HTPB as well as slight oxidation of Al particles. In the third stage, further oxidation of Al particles resulted in a small mass increase. Due to the continuous emission problem, only a few combustion intermediates were identified in the combustion emission spectrum curves. The propellant combustion process could be roughly divided into three stages, and the flame development stage lasted longer than the flame decline stage. As the pressure increased, the propellant ignition delay time decreased and the burning rate increased significantly. The effect of pressure on ignition delay was more pronounced at low pressures. The CCPs consisted of three types. The oxidation of Al particles in the propellant followed the diffusion reaction mechanism. Agglomerates appeared in several different morphologies and had relatively low combustion efficiency under experimental conditions. A 2-D pocket-like structure was observed on the propellant surface.