This study is focused on the micronization of p-toluenesulfonamide (p-TSA) using the rapid expansion of supercritical solution (RESS) process. Taguchi’s experimental design method was applied to determine the optimum operating conditions. L₉(3⁴) orthogonal array with four control factors and three levels of each control factor was used to design nine experimental conditions. Four control factors were selected, including extraction temperature, extraction pressure, pre-expansion temperature, and post-expansion temperature. The particle size and morphology of the prepared samples were observed by scanning electron microscopy (SEM). In addition, Fourier transform infrared spectrometer (FTIR), X-ray diffraction (XRD), and differential scanning calorimetry (DSC) were employed to compare the differences between the raw and micronized p-TSA particles. The experimental and analytical results indicated that the extraction temperature was the most significant factor for the micronization of p-TSA in the RESS process, and the optimal operating conditions were at an extraction temperature of 50 °C, an extraction pressure of 220 MPa, a pre-expansion temperature of 220 °C, and a post-expansion temperature of 30 °C. The p-TSA particles were micronized from the original average size of 294.8 μm to the smallest average size of 1.1 μm at the optimal RESS process conditions. Furthermore, the physicochemical characteristics of p-TSA did not differ significantly before and after recrystallization.

This study mainly explored the characteristics of NC/HTPB-based high-energy gun propellants with RDX, CL-20 or TKX-50 by experimental method. Three series of test samples were prepared referring to the formulation of M1 single-base gun propellant (M1 SBP). The thermochemical characteristics, chemical stability, explosion heat, impact and friction sensitivities of prepared samples were determined by simultaneous differential scanning calorimetry–thermogravimetric analysis (STA DSC–TGA), vacuum stability tester (VST), bomb calorimeter (BC), BAM fallhammer and BAM friction tester, respectively, and compared with those of the reference sample M1. The experimental results indicated that the thermochemical characteristics of NC/HTPB-based high-energy gun propellants were similar to those of M1 SBP. The NC/HTPB-based high-energy gun propellants had good chemical stability and were superior to M1 SBP. The explosion heat of NC/HTPB-based high-energy gun propellants was close to and slightly larger than that of M1 SBP. In addition, the NC/HTPB-based high-energy gun propellants had lower impact and friction sensitivities than the M1 SBP. Therefore, the NC/HTPB-based high-energy gun propellants have the potential to replace the M1 SBP. The combustion performances of NC/HTPB-based high-energy gun propellants will be continuously studied and verified in the future.