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Aluminium–lithium alloy (Al–Li alloy) powder has excellent ignition and combustion performance. The combustion product of Al–Li alloy powder combined with ammonium perchlorate is gaseous at the working temperature of solid rocket motors, which greatly reduces the loss of two-phase flow. Experimental investigations were thoroughly conducted to determine the effect of the Al–2.5Li (2.5 wt% lithium) content on propellant combustion and agglomeration based on thermogravimetry-differential scanning calorimetry, heat combustion, laser ignition, combustion diagnosis, a simulated 75 mm solid rocket motor and a condensed combustion products (CCPs) collection device. The results show that the exothermic heat and weight gain upon the thermal oxidation of Al–Li alloy is obviously higher than those of Al powder. Compared with the reference propellant’s formulation, Al–2.5Li leads to an increase in the burning rate and a decrease in the size of the condensed combustion products of the propellants. As the Al–2.5Li alloy content gradually increases from 0 wt% to 19 wt%, the burning rate increases from 5.391 ± 0.021 mm/s to 7.244 ± 0.052 mm/s at 7 MPa of pressure; meanwhile, the pressure exponent of the burning rate law is changed from 0.326 ± 0.047 to 0.483 ± 0.045, and the d43 of the combustion residue is reduced from 165.31 ± 36.18 μm to 12.95 ± 4.00 μm. Compared to the reference propellant’s formulation, the combustion efficiency of the HTPB propellant is increased by about 4.4% when the Al–2.5Li alloy content is increased from 0 to 19%. Therefore, Al–2.5Li alloy powder is a promising fuel for solid propellants.

To study the mechanical properties of highly filled hydroxy-terminated polybutadiene (HTPB) propellant with 90 wt% solid fillers, the stress–strain curves of the propellant under different temperatures (−50 to 70 °C) and strain rates (0.000476 to 0.119048 s−1) were obtained by uniaxial tensile test. Moreover, to obtain the glass transition temperature and understand the effect of low temperatures on the mechanical properties of the propellant, DMA experiments were carried out. On this basis, the mechanical response laws of the propellant were analyzed, and the master curves of mechanical properties were established. Furthermore, the fracture features of the propellant under typical loading conditions were obtained by SEM, and the corresponding failure mechanisms were analyzed. The results show that the maximum strength decreases with increasing temperature, while the maximum elongation increases with increasing temperature at the same strain rate. The maximum tensile strength increases with increasing strain rate, while the maximum elongation decreases with increasing strain rate at the same temperature. The maximum tensile strength is lowest with a value of 0.35 MPa when the temperature is 343.15 K and the strain rate is 0.000476 s−1, at which time the maximum elongation reaches the highest with a value of 44%. In terms of failure mechanisms, the propellant shows no particle fracture, and the failure modes of the propellant are mainly matrix tearing and dewetting.

The interfacial interaction between the main oxidant filler ammonium perchlorate (AP) and hydroxyl-terminated polybutadiene (HTPB) matrix in AP/HTPB propellants were studied via an all-atom molecular dynamics simulation. The results of the simulation showed the effects of the microscopic cross-linked structure of the matrix, stretching rate during uniaxial stretching, and contact area between the filler and matrix on the mechanical properties, such as the stress and strain of the composite solid propellant. Among the aforementioned factors, the stretching rate considerably affects the mechanical properties of the solid propellant, and the maximum stress of the solid propellant proportionally increases with the stretching rate. When defects were introduced on the surface of the AP filler, the contact area between the filler and matrix affected the strain type of the matrix molecules. Owing to the interaction between the molecules and atoms, the strain behaviour of the matrix molecule changed with the change in its microscopic cross-linked structure during uniaxial stretching. Molecular dynamics simulations were used to explore the characteristics at the AP–HTPB interface in AP/HTPB propellants. The aforementioned simulation results further revealed the interfacial interaction mechanism of the AP–HTPB matrix and provided a theoretical basis for the design of high-performance propellants.

The nonlinear mechanical behavior and temperature sensitivity of HTPB propellant for solid rocket motors were investigated. The rate-dependent mechanical properties of the propellant were examined through a combination of experiments and numerical simulations. Experimental results demonstrate that the tensile mechanical properties of HTPB propellant are rate-dependent at 223 K and 323 K; stresses at a given strain gradually increase with increasing strain rate. By use a generalized nonlinear ZWT intrinsic model, the tensile mechanical behavior of HTPB propellant under a wide range of strain rates was to described. A numerical simulation of a uniaxial tensile test was performed using a UMAT subroutine. The results demonstrate that the model accurately represents the mechanical properties of the HTPB propellant.

To investigate the structural effects of the mechanical heterogeneity of Hydroxyl-terminated polybutadiene (HTPB) propellant grain under ignition pressurization, a gradient finite element method was proposed to evaluate its structural integrity. The heterogeneous mechanical properties of the propellant grain were constructed and assessed. The results demonstrate that the mechanical properties of the propellant grain are spatially variable when taking into account the effect of the load. The range of variation in the mechanical properties is related to the size of the load and its effect on the mechanical properties of the propellant. Two key parameters that affect the mechanical response of the grain are the non-uniform distribution of the modulus and the damage strain threshold. An increase in the propellant modulus leads to an increase in the stress response and a decrease in the strain response of the propellant grain under ignition pressurization. Meanwhile, an increase in the damage strain threshold improves the propellant’s modulus in the linear elastic stage in a disguised form. This also leads to an increase in the stress response and a decrease in the strain response when the strain response exceeds the damage strain threshold. The safety factor, based on the equivalent strain failure criterion of the grain, directly depends on both the strain response of the propellant grain and the maximum elongation of the propellant. Furthermore, the change in the safety factor of two propellant grains is primarily affected by the maximum elongation of the propellant.

As a typical viscoelastic material, solid propellants have a large difference in mechanical properties under static and dynamic loading. This variability is manifested in the difference in values of the relaxation modulus and dynamic modulus, which serve as the entry point for studying the dynamic and static mechanical properties of propellants. The relaxation modulus and dynamic modulus have a clear integral relationship in theory, but their consistency in engineering practice has never been verified. In this paper, by introducing the “catch-up factor λ” and “waiting factor γ”, a method for the inter-conversion of the dynamic storage modulus and relaxation modulus of HTPB propellant is established, and the consistency between them is verified. The results show that the time region of the calculated conversion values of the relaxation modulus obtained by this method covers 10−8–104 s, spanning twelve orders of magnitude. Compared to that of the relaxation modulus (10−4–104 s, spanning eight orders of magnitude), an expansion of four orders of magnitude is achieved. This enhances the expression ability of the relaxation modulus on the mechanical properties of the propellant. Furthermore, when the conversion method is applied to the dynamic–static modulus conversion of the other two HTPB propellants, the results show that the correlation coefficient between the calculated and measured conversion values is R2 > 0.933. This proves the applicability of this method to the dynamic–static modulus conversion of other types of HTPB propellants. It was also found that λ and γ have the same universal optimal value for different HTPB propellants. As a bridge for static and dynamic modulus conversion, this method greatly expands the expression ability of the relaxation modulus and dynamic storage modulus on the mechanical properties of the HTPB propellant, which is of great significance in the research into the mechanical properties of the propellant.

In this study, we explored the evolution of mechanical properties in hydroxyl-terminated polybutadiene (HTPB) propellants under fatigue loading by performing fatigue tests with varying maximum stresses and cycle numbers, followed by uniaxial tensile tests on post-fatigue specimens. Residual elongation was used as a key parameter to characterize mechanical behavior, while scanning electron microscopy (SEM) provided insights into the mesostructural morphological changes that occur under different loading conditions, revealing the mechanisms responsible for variations in mechanical properties. The results show that, as the number of loading cycles increases, residual elongation decreases, with three distinct phases of decline—slow change, gradual decline, and rapid deterioration—depending on the stress levels. SEM analysis identified damage mechanisms such as “dewetting” and particle fragmentation at the mesostructural level, which compromise the material’s structural integrity, leading to reduced residual elongation. A novel aspect of this study is the application of Williams–Landel–Ferry (WLF) theory to construct a master curve describing residual elongation decay. This approach enabled the development of a generalized model to predict the material’s degradation under fatigue loading, with experimental validation of the fitted evolution model, offering a new and effective method for assessing the long-term performance of HTPB propellants.

The present study proposes a method to estimate the microflame properties of ammonium perchlorate/hydroxyl-terminated polybutadiene (AP/HTPB) propellant at different binder widths. A 3D random particle packing is generated by the Monte Carlo method. A transformation from Miller packing to sandwich model is used by the dual slicing technique. The gas-solid coupling model and the two-step BDP flame model in the combustion field are established to study the influence of kinetic chemical and fluid diffusion process on the micrflame properties. Finally, the mathematical relationships of the burning rate r b and the final flame height H 3 on the HTPB thickness D are obtained by analyzing and fitting combustion processes of multiple AP/HTPB propellants, namely, and H 3 = −0.04 D 3 +1.22 D 2 –13.07 D +67.73 .

In this paper, high cis-1,4 content hydroxyl-terminated polybutadiene (cis-HTPB) with different molecular weights was prepared through the oxidative cracking process using cis-butadiene rubber as raw material. Firstly, this article comprehensively compared the differences between cis-HTPB and conventional I-HTPB in terms of molecular weight distribution, functionality, viscosity, molecular polarity, and other physicochemical properties, which provided effective data support for its subsequent application. In addition, the reaction kinetics study showed that cis-HTPB with isocyanate curing agent has high reactivity, allowing it to be rapidly cured at low temperatures, and the cured elastomers had excellent mechanical properties, with tensile strength and elongation up to 1.89 MPa and 1100%, respectively. It was also found that cis-HTPB has extremely excellent low-temperature resistance, and the glass transition temperature (Tg) of its cured elastomer is as low as −101 °C. Based on the above studies, cis-HTPB is applied as a binder in composite solid propellants for the first time to investigate its practical performance, and the results indicated that cis-HTPB-based propellants have excellent process and mechanical properties. [Display omitted] •There are many differences between cis-HTPB and free radical HTPB in some physicochemical parameters.•The reactivity of cis-HTPB is higher than the traditional HTPB.•cis-HTPB/IPDI elastomer has excellent low temperature resistance and mechanical properties.•The application effect of cis-HTPB in composite solid propellant is good.

To investigate the aging behavior of HTPB composite solid propellant under constant strain conditions, this study analyzed the aging patterns of the propellant’s maximum elongation at four temperatures (323.15 K–343.15 K) and five strain levels (0–18%) using thermal–mechanical coupled accelerated aging tests. The results show that the maximum elongation initially increases, then decreases under constant strain conditions. To measure the mechanical work-induced decrease in the activation motor, we created a modified Arrhenius model with a strain correction factor based on empirical observations. The acceleration coefficient of a solid motor grain at the accelerated aging temperature (323.15 K) in comparison to the long-term storage temperature (293.15 K) was found to be 20.08 through finite element analysis. This means 206.80 days at the accelerated aging temperature is equivalent to 10 years at the long-term storage temperature.