To improve the combustion stability and ignition performance of thermite, B/NC/CuO micro particles were prepared from boron (B), nano copper oxide (CuO), and nitrocellulose (NC) as an energetic binder through the electrospray technique. The burning rate dependency on boron content, ambient temperature, and pressure was estimated by compressing B/NC/CuO micro particles into columns. Scanning electron microscopy results show that the sizes of these particles mostly lie in the range of 3–4 μm. The particles are ignitable and burn consistently with minor variations in the conditions: B content (8.3–17%), ambient temperature (−50–55 °C), and ambient pressure (0.02–0.1 MPa). The optimum formula was observed for micro particles with 11 wt% B content. Compared with the ball milling sample, the standard deviation of the burning rate of the electrosprayed sample was reduced by 32%. Combustion is barely affected by ambient pressure. Between −50 °C to 55 °C, the burning rate of B/NC/CuO increases by 14.16% from an initial rate of 13.35 mm⋅s⁻¹. In addition, the laser ignition energy required for B/NC/CuO microparticles was also reduced from 70 to 45 mJ.

The effects of flame retardant silica (SiO₂) and magnesium hydroxide (Mg(OH)₂) on the thermal decomposition process of polyimide (PI) are discussed in this paper. Firstly, the decomposition process of PI in a nitrogen and oxygen atmosphere was studied by thermogravimetric analysis and differential scanning calorimetry methods, and the kinetic parameters were calculated by the nonlinear fitting method. In an inert atmosphere, PI decomposition consists of a three-step endothermic reaction, whereas in an oxygen atmosphere, PI decomposition consists of two steps, in which the first step does not change, and the second step changes to a violent exothermic peak. The effects of 3 wt % SiO₂ (SPI) and 3 wt % Mg(OH)₂ (MPI) on the degradation kinetics of PI are discussed. The results show that under an oxygen atmosphere, SiO₂ and Mg(OH)₂ hydroxide mainly delayed the second-step oxidation exothermic peak temperature of PI by 5 °C. In summary, the first step of the PI degradation is not affected by oxygen, and the flame retardant mainly acts in the second step, which can delay the oxidation heat release. In addition, the addition of SiO₂ could prevent PI from aging whereas Mg(OH)₂ has barely effect on the aging of PI.

A thorough investigation on the reactions and morphologies of Mg particles and Mg/Teflon/Viton (MTV) during oxidation were conducted via thermal gravity-differential scanning calorimetry (TG-DSC) and scanning electronic microscopy. The results showed that the oxidation of Mg is fast. It merely changed the metallic luster of Mg before 550 °C, and only a few particles changed to a white irregular shape at 600 °C. However, all of the Mg particles oxidized to porous irregular shaped MgO at 650 °C. Herein, the oxidation of Mg particles ended by its melting point, and the whole process is a solid–gas-phase reaction. On the other hand, when MTV reacted in air, the reaction could be divided into two stages: the fluorination of Mg and the oxidation of the exceeded Mg. In the first stage, a dense MgF₂ shell was formed by the solid–solid fluorination. The dense MgF₂ shell could impede the oxidation of Mg. As a result, the oxidation of Mg began after its melting. Furthermore, liquid Mg could vaporize at higher temperature, which could burst out from the MgF₂ shell and react with oxygen. The MgF₂ shell exhibited a dense feature, not only protecting the Mg particles from the heterogeneous oxidation at lower temperature, but also facilitates the homogeneous oxidation at higher temperature.

During long-term storage, polymer-bonded explosives (PBXs) undergo thermal-oxidative aging due to environmental factors such as moisture and oxygen, which leads to a critical determinant of explosive performance. This study employed molecular dynamics simulations to investigate the impact of thermal-oxidative aging of butadiene rubber and paraffin wax composites used in the RDX-based polymer-bonded explosives. The interfacial binding energy between the binder system and RDX crystalline surfaces was evaluated. The cohesive energy density (CED), fractional free volume (FFV), mean square displacement (MSD), and mechanical properties were analysed to probe the mechanism of aging for butadiene rubber (BR) and paraffin wax (PW). The results demonstrate that, with progressive aging, the oxidation-induced chain scission of BR molecules leads to an increase in both the CED and solubility parameter of the BR/PW system. Initial oxidation reduces the FFV of the BR/PW system from 0.183 to 0.166, while subsequent chain scission causes the FFV to rise to 0.175. In terms of mechanical properties, the BR/PW system exhibits ductile behavior, with reductions in both Young’s modulus and shear modulus as aging progresses, leading to decreased material stiffness. For the RDX/binder system, oxidation enhances the interfacial binding energy, whereas chain scission in BR leads to a slight decline in the binding energy. Overall, oxidation exerts a more pronounced influence on the interfacial binding energy compared to chain scission.