Preparation of mono-dispersed, high energy release, core/shell structure Al nanopowders and their application in HTPB propellant as combustion enhancers

Mono-dispersed, spherical and core/shell structure aluminum nanopowders (ANPs) were produced massively by high energy ion beam evaporation (HEIBE). And the number weighted average particle size of the ANPs is 98.9 nm, with an alumina shell (3–5 nm). Benefiting from the passivation treatment, the friction, impact and electrostatic spark sensitivity of the ANPs are almost equivalent to those of aluminum micro powders. The result of TG-DSC indicates the active aluminum content of ANPs is 87.14%, the enthalpy release value is 20.37 kJ/g, the specific heat release S (1)/Δm (1)* (392–611 °C) which determined the ability of energy release is 19.95 kJ/g. And the value of S (1)/Δm (1)* is the highest compared with ANPs produced by other physical methods. Besides, the ANPs perfectly compatible with hydroxyl-terminated polybutadiene (HTPB), 3 wt. % of ANPs were used in HTPB propellant replaced micron aluminum powders, and improved the burning rate in the 3–12 MPa pressure range and reduced the pressure exponential by more than 31% in the 3–16 MPa pressure range. The production technology of ANPs with excellent properties will greatly promote the application of ANPs in the field of energetic materials such as propellant, explosive and pyrotechnics.