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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This thesis presents a study on two types of X-ray diffraction methodologies applied to the characterization of amorphous materials. The purpose of this study was to assess the feasibility of measuring the diffractive spectrum of amorphous materials by Energy-Dispersive X-ray Diffraction (EDXRD) utilizing Cadmium Zinc Telluride detectors. The total scattering intensity (coherent plus incoherent scatter) spectra precisely measured by high-energy Wide-Angle X-ray Scattering (WAXS) were compared to the EDXRD spectra to determine the level of agreement between the two techniques. The EDXRD spectra were constructed by applying a spectra fusing technique which combined the EDXRD spectra collected at different scattering angles rendering a continuous total scattering spectrum. The spectra fusing technique extended the momentum transfer range of the observed scattered spectrum beyond the limitations of the X-ray source and CZT detection efficiencies. Agreement between the WAXS and fused EDXRD spectra was achieved. In addition, this thesis presents the atomic pair correlation functions and coordination numbers of the first coordination shell for four hydrogen peroxide solutions of varying mass concentrations using Empirical Potential Structural Refinement (EPSR). The results are compared to the state-of-the art ad initio quantum mechanical charge field molecular dynamics (QMCF MD) model of the hydrogen peroxide in solution to support the model's predictions on why hydrogen peroxide is stable in water. The EPSR results using the coherent scattering intensity calculated from the WAXS data set predicts a hydration shell of 6.4 molecules of water surrounding hydrogen peroxide. The results also indicate that hydrogen peroxide is more likely to behave as a proton donor than acceptor. These findings are in agreement with QMCF MD model of aqueous hydrogen peroxide. / Physics

This dissertation presents a discussion of blocky and randomly functionalized sulfonated syndiotactic polystyrene copolymers. These copolymers have been prepared over a range of functionalization (from 2% to 10%) in order to assess the effect of the incorporation of these polar side groups on both the thermal behavior and morphology of these polymer systems. The two different architectures are achieved by conducting the reaction in both the heterogeneous gel-state to obtain blocky copolymers and in the homogeneous solution state to obtain randomly functionalized copolymers. In order to compare both the thermal properties and morphology of these two systems several sets of samples were prepared at comparable levels of sulfonation. Thermal analysis of these two systems proved that the blocky functionalized copolymers provided superior properties with regard to the speed and total amount of the crystalline component of sulfonated syndiotactic polystyrene. Above 3% functionalizion the randomly functionalized copolymer was no longer able to crystallize, whereas, the blocky functionalized copolymer is able to crystallize even at a functionalization level of 10.5% sulfonate groups. When considering the morphology of these systems even at low percentages of sulfonation it is clear that the distribution of these groups is different based on the amplitude of the signal measured by small angle x-ray scattering. Additionally, methods were developed to describe both the distribution of ionic multiplets, which varies between blocky and randomly functionalized systems, but also the distribution of crystals. At a larger scale ultra-small angle x-ray scattering was employed to attempt to understand the clustering of ionic multiplets in these systems. Randomly functionalized polymers should a peak that is attributed to ion clusters, whereas blocky polymers show no such peak. Additional studies have also been done to look at the analysis of crystallite sizes in these systems when there are multiplet polymorphs present, it was observed the polymorphic composition is drastically different. All of these studies support that these systems bear vastly different thermal behavior and possess significantly different morphologies. This supports the hypothesis that this gel-state heterogeneous functionalization procedure produces a much different chain architecture compared to homogeneous functionalization in the solution-state. / Doctor of Philosophy / Polymers are a class of chemicals that are defined by having a very large set of molecules that are chemically linked together where each unit (monomer) is repeated within the chemical structure. In particular, this dissertation focuses on the construction what are termed as "blocky" copolymers, which are defined by having two chemically different monomers that are incorporated in the polymer chain. The "blocky" characteristic of these polymers means that these two different monomers are physically segregated from each other on the polymer chain, where long portions of the chain that are of one type, followed by another section of the polymer that has the other type of monomer. The goal of creating this type of structure is to try to take advantage of the properties of both types of monomers, which can create materials with superior synergistic properties. In this case a hydrophobic (water hating) monomer is combined with a hydrophilic (water loving) chain. This hydrophobic component in the polymer is able to crystallize, which provides mechanical and thermal stability in the material by acting as a physical tether to hold neighboring chains together. With the other set of hydrophilic monomers, which in this case have an ionic component incorporated, we can now take advantage of this chemical components ability to aide in the transportation of ions. Transportation of ions is useful in a variety of commercially relevant applications, two of the most important applications of these ionic materials is in membranes that can be used to purify water or membrane materials in fuel cell technologies, specifically for proton exchange membranes. The focus of this research in particular was to create a simple synthesis technique that can create these blocky polymer chain architectures, which is done by performing the reaction while the polymer is made into a gel. The key to this is that the crystals within the gel act as a barrier to chemical reactions, creating conditions where we have substantial portions of the material that are able to be functionalized and the crystals within the material that are protected from being functionalized. By looking at the thermal characteristics, such as melting temperatures and amount of crystals within these systems we have seen that functionalizing these polymers in the heterogeneous gel state gives substantially better properties than functionalizing these materials randomly. Much like oil and water, incompatible polymer chains will phase separate from each other. In this case the hydrophobic and ionic components will phase separate from each other. The shape and distribution of these phase separated structure will dictate many of the material properties, which can be described by modeling the data collected from x-ray scattering experiments. All of this information will tell us based on the initial conditions that these polymers were created in, what properties should be expected based on the morphology and thermal behavior. This gives a better understanding of how to fine tune these properties based on the structure of the gel and chemical reaction conditions.

The ability to quickly develop predictions of the time-to-failure under different loading levels allows designers to choose the best polymeric material for a specific application. Additionally, it helps material producers to design, manufacture, test, and modify a polymeric material more rapidly. In the case of polymeric pipes, previous studies have shown that there are two possible time-dependent failure mechanisms corresponding to ductile and brittle failure. The ductile mechanism is evident at shorter times-to-failure and results from the stretching of the amorphous region under loading and the subsequent plastic deformation. Empirical results show that many high-performance polyethylene (PE) materials do not exhibit the brittle failure mechanism. Hence, it is critical to understand the ductile mechanism and find an approach to predict the corresponding times-to-failure using accelerated means. The aim of this study is to develop an innovative rupture lifetime acceleration protocol for PE pipes which is sensitive to the structure, orientation, and morphology changes introduced by changing processing conditions. To accomplish this task, custom fixtures are developed to admit tensile and hoop burst tests on PE pipes. A pressure modified Eyring flow equation is used to predict the rupture lifetime of PE pipes using the measured mechanical properties under axial tensile and hydrostatic pressure loading in different temperatures and strain rates. In total, the experimental method takes approximately one week to be completed and allows the prediction of pipe lifetimes for service lifetime in excess of 50 years. / Master of Science / Steel, cast and galvanized iron, and asbestos cement (AC) pipelines have been historically used in water management services. However, they often experienced deterioration because of corrosion and encrustation, resulting in 23 to 27 bursts per 100 miles of pipeline in the US per year. Therefore, plastic pipes were developed to carry liquids (water and sewage), gases, etc. The Plastic Pipe Institute (PPI) requires a service life of at least 50-years for plastic pipes. Hence, pipe producers and material suppliers continuously attempt to improve the materials and manufacturing processes used for plastic pipes to increase their service lifetimes. However, there is still no plastic pipe that has been in service for 50 years. Therefore, a few techniques have been developed to accelerate the aging process and to predict if the plastic pipe is able to endure the 50-year lifetime without failure. In this work, a combined experimental and analytical framework is presented to develop accelerated lifetime estimates for plastic pipes. Custom axial tensile and internal pressurization fixtures are developed to measure the pipe response; the analytical method is used to extend the results to predict 50-year (and beyond) behavior.