There exists wide ranging research interest in high-energy-density matter (HEDM) propellants as a potential replacement for existing industry standard fuels for liquid rocket engines. The U.S. Air Force Research Laboratory, the U.S. Army Research Lab, the NASA Marshall Space Flight Center, and the NASA Glenn Research Center each either recently concluded or currently has ongoing programs in the synthesis and development of these potential new propellants. In order to perform conceptual designs using these new propellants, most conceptual rocket engine powerhead design tools (e.g. NPSS, ROCETS, and REDTOP-2) require several thermophysical properties of a given propellant over a wide range of temperature and pressure. These properties include enthalpy, entropy, density, viscosity, and thermal conductivity. Very little thermophysical property data exists for most of these potential new HEDM propellants. Experimental testing of these properties is both expensive and time consuming and is impractical in a conceptual vehicle design environment. A new technique for determining these thermophysical properties of potential new rocket engine propellants is presented. The technique uses a combination of three different computational methods to determine these properties. Quantum mechanics and molecular dynamics are used to model new propellants at a molecular level in order to calculate density, enthalpy, and entropy. Additivity methods are used to calculate the kinematic viscosity and thermal conductivity of new propellants. This new technique is validated via a series of verification experiments of HEDM compounds. Results are provided for two HEDM propellants: quadricyclane and 2-azido-N, N-dimethylethanamine (DMAZ). In each case, the new technique does a better job than the best current computational methods at accurately matching the experimental data of the HEDM compounds of interest. A case study is provided to help quantify the vehicle level impacts of using HEDM propellants. The case study consists of the National Aeronautics and Space Administrations (NASA) Exploration Systems Architecture Study (ESAS) Lunar Surface Access Module (LSAM). The results of this study show that the use of HEDM propellants instead of hypergolic propellants can lower the gross weight of the LSAM and may be an attractive alternative to the current baseline hypergolic propellant choice.

The manufacturing process for solventless extruded double base propellants involves a number of rolling and reworking stages. Throughout these processes a decrease in weight average molecular weight was observed, this was attributed to denitration. Differential scanning calorimetery data indicated that the reworking stages of extruded double base propellant manufacture were crucial to the homogenisation of the propellant mixture. To determine the homogeneity of the final extruded product, a sample was analysed across its diameter. No variations in stabiliser concentration, molecular weight, or Vickers hardness were detected. An accelerated thermal ageing trial simulating up to 8 years of ageing at 25°C was carried out to evaluate the storage characteristics. Reductions in stabiliser concentration, number average molecular weight, weight average molecular weight and polydispersity compared with un-aged samples were observed. The glass transition temperature measured using differential scanning calorimetery decreased by ~3°C. The decrease was attributed to the initial denitration reducing the energy of bond rotation and shortening the polymer chains, both factors reducing the energy required for movement. Modulus values determined from dynamic mechanical analysis temperature scanning experiments, did not detect significant variation between un-aged and aged samples. Though it was considered that variations would be likely if a more extensive ageing program was completed. In order to evaluate propellant behaviour at very high and low frequencies, time temperature superposition (TTS) and creep testing were carried out. The TTS technique superpositioned data well, allowing future investigation of high frequency propellant properties. Creep testing was considered to be an appropriate approach, though the equipment available was not optimised for such testing. This thesis is concerned with understanding how propellants are manufactured from nitrocellulose, nitroglycerine and other constituents. It is also about how the propellants decompose during long periods of time in storage, and how these changes can be measured using thermal and mechanical methods. It is about how the physical, chemical and thermal properties of the propellant composition change throughout the manufacture. This is relevant as it could be used to develop more efficient manufacturing processes, allow operators to adjust processes to tailor product properties or be used to re-design manufacturing to compensate for a different starting material. The thesis also considers how and why the properties of the product change over the course of years of storage. A specific focus on whether changes in mechanical and thermal properties occur, and if so how they can be detected.

The manufacturing process for solventless extruded double base propellants involves a number of rolling and reworking stages. Throughout these processes a decrease in weight average molecular weight was observed, this was attributed to denitration. Differential scanning calorimetery data indicated that the reworking stages of extruded double base propellant manufacture were crucial to the homogenisation of the propellant mixture. To determine the homogeneity of the final extruded product, a sample was analysed across its diameter. No variations in stabiliser concentration, molecular weight, or Vickers hardness were detected. An accelerated thermal ageing trial simulating up to 8 years of ageing at 25°C was carried out to evaluate the storage characteristics. Reductions in stabiliser concentration, number average molecular weight, weight average molecular weight and polydispersity compared with un-aged samples were observed. The glass transition temperature measured using differential scanning calorimetery decreased by ~3°C. The decrease was attributed to the initial denitration reducing the energy of bond rotation and shortening the polymer chains, both factors reducing the energy required for movement. Modulus values determined from dynamic mechanical analysis temperature scanning experiments, did not detect significant variation between un-aged and aged samples. Though it was considered that variations would be likely if a more extensive ageing program was completed. In order to evaluate propellant behaviour at very high and low frequencies, time temperature superposition (TTS) and creep testing were carried out. The TTS technique superpositioned data well, allowing future investigation of high frequency propellant properties. Creep testing was considered to be an appropriate approach, though the equipment available was not optimised for such testing. This thesis is concerned with understanding how propellants are manufactured from nitrocellulose, nitroglycerine and other constituents. It is also about how the propellants decompose during long periods of time in storage, and how these changes can be measured using thermal and mechanical methods. It is about how the physical, chemical and thermal properties of the propellant composition change throughout the manufacture. This is relevant as it could be used to develop more efficient manufacturing processes, allow operators to adjust processes to tailor product properties or be used to re-design manufacturing to compensate for a different starting material. The thesis also considers how and why the properties of the product change over the course of years of storage. A specific focus on whether changes in mechanical and thermal properties occur, and if so how they can be detected. / © Cranfield University

Composite propellants are mainly composed of: crystalline oxidizer, metallic fuel, and polymeric binder. Additives, such as plasticizers, catalysts, bonding agents and curing agents may also be incorporated to propellant compositions in small amounts. These ingredients should be mixed rigorously in order to obtain a uniform microstructure throughout the cast propellant profile. The quality of the propellant mixture has to be determined quantitatively to improve the product quality and to reduce costs. In this study, it was aimed to develop an easy, cost effective and rapid test method for determining the optimum mixing conditions for the manufacturing process of solid rocket propellants. An analytical method used in the literature for assessing mixing quality in highly filled polymeric systems is wide-angle x-ray diffractometry (WA-XRD). After finding out the concentration distribution of the components indirectly by WA-XRD, degree of mixing was identified using statistical methods. To accomplish this, series of samples were taken from various locations of the mixing chamber and analyzed by WA-XRD. Degree of mixing calculations based on ratio of intensity arising from aluminum phase over total crystal intensity, and the ratio of intensity arising from ammonium perchlorate phase over total crystal intensity gave satisfactory results. Radial mixing efficiency of planetary mixer was determined, and it was found that mixing at the center was more effective than mixing at the outer regions. Also, by scanning electron microscopy technique (SEM), interactions between binder and solid loading during mixing process were observed. It was seen that polymeric matrix gradually encloses solid particles during mixing.

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To enable future environmentally friendly access to space by means of solid rocket propulsion a viable replacement to the hazardous ammonium perchlorate oxidizer is needed. Ammonium dinitramide (ADN) is one of few such compounds currently known. Unfortunately compatibility issues with many polymer binder systems and unexplained solid-state behavior have thus far hampered the development of ADN-based propellants. Chapters one, two and three offer a general introduction to the thesis, and into relevant aspects of quantum chemistry and polymer chemistry. Chapter four of this thesis presents extensive quantum chemical and spectroscopic studies that explain much of ADN’s anomalous reactivity, solid-state behavior and thermal stability. Polarization of surface dinitramide anions has been identified as the main reason for the decreased stability of solid ADN, and theoretical models have been developed to explain and predict the solid-state stability of general dinitramide salts. Experimental decomposition characteristics for ADN, such as activation energy and decomposition products, have been explained for different physical conditions. The reactivity of ADN towards many chemical groups is explained by ammonium-mediated conjugate addition reactions. It is predicted that ADN can be stabilized by changing the surface chemistry with additives, for example by using hydrogen bond donors, and by trapping radical intermediates using suitable amine-functionalities. Chapter five presents several conceptual green energetic materials (GEMs), including different pentazolate derivatives, which have been subjected to thorough theoretical studies. One of these, trinitramide (TNA), has been synthesized and characterized by vibrational and nuclear magnetic resonance spectroscopy. Finally, chapter six covers the synthesis of several polymeric materials based on polyoxetanes, which have been tested for compatibility with ADN. Successful formation of polymer matrices based on the ADN-compatible polyglycidyl azide polymer (GAP) has been demonstrated using a novel type of macromolecular curing agent. In light of these results further work towards ADN-propellants is strongly encouraged. / QC 20101103