This program will lead to advanced high energy density composite metallized propellants that will ignite faster, burn more completely, more rapidly, and with less agglomeration than presently used fuels and thus, greatly improve rocket motor performance. Powder will be produced through a novel combustion process that couples industry-standard chemistry with a proven industrial powder production system. This process yields metal nanoparticles that are coated with sodium chloride, which serves as a protective barrier for safe handling and storage in air. Prior to implementation into propellant formulations, these powders will be processed to remove the sodium chloride and apply a protective coating that constitutes only a minor fraction of the total mass, thus maximizing performance of the particles. To-date, exploitation of nanomaterials in propulsion applications has been hindered by the high cost and highly reactive nature of nanopowders. During Phase I, to demonstrate feasibility, aluminum nanoparticles will be produced, processed, and tested in laboratory combustion tests. In addition to demonstrating the improved performance of propellant materials, the program will enable production of a broad range of technologically important materials because the production and processing technologies are generic and will thus enhance the leadership role of the U.S. in advanced materials. Anticipated Benefits/Commercial Applications: This program will produce a new class of advanced propellants by exploiting the unique properties of high purity metal nanopowders. A low-cost domestic source of high purity, low oxygen metal nanoparticles will open up many markets in metal-based high energy density materials for propulsion and explosives, both in the U.S. military and in commercial applications. Furthermore, the generic technology enables production of a broad range of nanomaterials and opens up many markets in the automotive, biomedical, defense, electronics, and other industries. Both the U.S. military and commercial sector are demanding substantial advances in such technologies and the proposed materials offer a realistic scenario for achieving these goals.
Keywords: Sodium flame and encapsulation, SFE, non-oxide, metal nanopowder, combustion synthesis, propulsion, aluminum propellants, Nanothin Coating
