Review of the Problems of Additive Manufacturing of Nanostructured High-Energy Materials

Additive Manufacturing and Combustion Characteristics of Polyethylene Oxide/Aluminum/Copper Oxide-Based Energetic Nanocomposites for Enhancing the Propulsion of Small Projectiles

The application of nanoscale energetic materials (nEMs) composed of metal and oxidizer nanoparticles (NPs) in thermal engineering systems is limited by their relatively high sensitivity and complex three-dimensional (3D) formability. Polymers can be added to nEMs to lower the sensitivity and improve the formability of 3D structures. In this study, the effect of the addition of polyethylene oxide (PEO; polymer) on the combustion characteristics of aluminum (Al; fuel)/copper oxide (CuO; oxidizer)-based nEMs is investigated. With an increase in the PEO content, the resulting PEO/nEM composites are desensitized to relatively high electrical spark discharges. However, the maximum explosion-induced pressure decreases significantly, and the combustion flame fails to propagate when the PEO content exceeds 15 wt.%. Therefore, the optimal PEO content in a nEM matrix must be accurately determined to achieve a compromise between sensitivity and reactivity. To demonstrate their potential application as composite solid propellants (CSPs), 3D-printed disks composed of PEO/nEM composites were assembled using additive manufacturing. They were cross-stacked with conventional potassium nitrate (KNO₃)/sucrose (C₁₂H₂₂O₁₁)-based disk-shaped CSPs in a combustion chamber of small rocket motors. Propulsion tests indicated that the specific impulse of KNSU/PEO/nEM (nEMs: 3.4 wt.%)-based CSPs was at a maximum value, which is approximately three times higher than that of KNSU CSPs without nEMs. This suggests that the addition of an optimized amount of polymer to nEMs is beneficial for various CSPs with compromised sensitivity and reactivity and excellent 3D formability, which can significantly enhance the propulsion of small projectiles.

Mathematical modeling of high-energy materials rheological behavior in 3D printing technology

In this paper, a mathematical model of the extrusion process in 3D printing of high-energy composites is studied. These composites are formed from polymer binder and powder with bimodal particles obtained by electric explosion technique. The main difficulty of extrusion 3D printing method is primarily linked to the high viscosity of utilized material, especially one with high concentration of particles. In this case, the viscosity of the initial mixture depends on the pressure, temperature and concentration of the filler, as well as on the particle dispersion. Under certain conditions the ignition of high-energy material in the nozzle is possible, thus the search for optimal printing parameters based on the mathematical modeling and the following experimental verification are the main purposes of the current work.

The Effect of Nano-ZrO2 Dispersed Phase into Cobalt Plating Electrolyte on Layer Thickness and Current Efficiency

The aim of this work is to obtain nanocomposite layers having a cobalt matrix with zirconium oxide nanoparticles (mean diameter 30 nm) through the electrodeposition process. The plating electrolyte suspension is prepared by adding ZrO2 nanoparticles in a sulfate-chloride cobalt electrolyte at a concentration of 0 and 10 g·L−1. The electrodeposition is performed at room temperature, using three current densities of 23, 48 and 72 mA·cm−2 and three deposition times of 30, 60 and 90 min. The influence of current density, time and nanoparticles concentrations on the characteristics of the obtained nanostructured layers are also discussed. ZrO2 ceramic nanoparticles as a dispersed phase in the cobalt deposition electrolyte modify the mechanism of its electro-crystallization, so they participate in this process by increasing the rate of cobalt deposition, confirmed by the thickness of the nanocomposite layers obtained. The paper presents some of the comparative results obtained regarding the thickness of the layers, the current efficiency and the inclusion of the nanoparticles into nanocomposite layers depending on the current density and time of the electrodeposition process. The analysis of Co/nano-ZrO2 nanocomposite layers with the help of optical light microscopy and electronic microscopy in cross-section highlights the good degree of adhesion of the layers to the metallic substrate made of 304L stainless steel. The results of the study show that as the current density and time increase, the thickness of the composite layers increases. The efficiency of the process is improved compared to the electrodeposition of pure cobalt layers. The degree of inclusion of ZrO2 nanoparticles increases with time and decreases with increasing of imposed current density on the electrodeposition process. The distribution of the dispersed phase in the cobalt metallic matrix is uniform. The layers obtained in this study can be applied in aircraft technology, in the automotive industry, as well as in biomedical applications in order to improve the properties and to increase the corrosion or tribocorrosion resistance in a specific environment.