The crystal structure has a great influence on mechanical sensitivity and detonation performance of energetic materials. An efficient microfluidic platform was applied for size, morphology, and crystallinity controllable preparation of ultrafine HMX. The microfluidic platform has good mixing performance, quick response, and less reagent consumption. The ultrafine γ-HMX was first prepared at room temperature by microfluidic strategy, and the crystal type can be controlled accurately by adjusting the process parameters. With the increase in flow ratio, the particle size decreases gradually, and the crystal type changed from β-HMX to γ-HMX. Thermal behavior of ultrafine HMX shows that γ→δ is easier than β→δ, and the phase stability of HMX is β > γ > δ. Furthermore, the ultrafine β-HMX has higher thermal stability and energy release efficiency than that of raw HMX. The ultrafine HMX prepared by microfluidic not only has uniform morphology and narrow particle size distribution, but also exhibits high density and low sensitivity. This study provides a safe, facile, and efficient way of controlling particle size, morphology, and crystallinity of ultrafine HMX.

1,3,5-trinitro-1,3,5-triazacyclohexane (RDX) is a type of high energy explosive, its application in weapon systems is limited by its high mechanical sensitivity. At the same time, 1,1-diamino-2,2-dinitroethylene (FOX-7) is a famous insensitive explosive. The preparation of RDX@FOX-7 composites can meet the requirements, high energy and low sensitivity, of the weapon systems. It is difficult for the reactor to achieve uniform quality of composite material, which affects its application performance. Based on the principle of solvent-anti-solvent, the recrystallization process was precisely controlled by microfluidic technology. The RDX@FOX-7 composites with different mass ratios were prepared. At the mass ratio of 10%, the RDX@FOX-7 composites are ellipsoid of about 15 μm with uniform distribution and quality. The advantages of microscale fabrication of composite materials were verified. The results of structure characterization showed that there is no new bond formation in RDX@FOX-7, but the distribution of two components on the surface of the composite was uniform. Based on the structure characterization, we established the structure model of RDX@RDX-7 and speculated the formation process of the composites in microscale. With the increase of FOX-7 mass ratios, the melting temperature of RDX was advanced, the thermal decomposition peak of RDX changed to double peaks, and the activation energy of RDX@FOX-7 composite decreased. These changes were more pronounced between 3 and 10% but not between 10 and 30%. The ignition delay time of RDX@FOX-7 was shorter than that of RDX and FOX-7. RDX@FOX-7 burned more completely than RDX indicating that FOX-7 can assist heat transfer and improve the combustion efficiency of RDX.

Structural regulation is of great significance for improving the comprehensive performance of energetic materials (EMs). The structural regulation and properties of EMs were summarized. For single-component EMs, particle size control focuses on quality consistency and industrial scalability, morphology modification mainly improves sphericity through monomers or aggregates and explores the possibility of layered energetic materials in improving mechanical properties, and polycrystalline regulation suppresses metastable phases and explores novel crystalline forms using simulation-guided design. Composite EMs (CEMs) employ core–shell structures to balance safety with performance via advanced coating materials, cocrystal engineering to tailor energy release through intermolecular interactions, and lattice strain modulation, and mixing structures integrates component advantages while enhancing the reaction efficiency. Future directions emphasize computational simulations and novel fabrication methods to guide the rational design and precise preparation of next-generation EMs with specific functions.

As a typical high-energy-density material, the sensitivity of CL-20 severely limits its application in explosives and propellants. Adjusting its structure at the microscopic level can effectively solve such problems. In this study, a microfluidic recrystallization technique was used to prepare ε-CL-20 with three different particle sizes, with narrow particle size distributions (D₅₀ = 2.77 μm, 17.22 μm and 50.35 μm). The prepared samples had fewer surface defects compared to the raw material. As the particle size decreased, the density of CL-20 increased and its impact sensitivity was significantly reduced. The activation energy of the CL-20 prepared using microfluidic technology increased with increases in particle size. Laser ignition experiments revealed that smaller CL-20 particles had the highest energy release efficiency, while larger particles exhibited a higher energy density and more stable energy release. The combustion performance and safety of CL-20 can be effectively improved by improving the crystal size distribution and surface morphology. Controllable preparation of multiple particle sizes of CL-20 was achieved using microfluidic recrystallization technology, which provides a reference for the preparation of multiple particle sizes of other energetic materials.

The combustion behavior of various propellant samples, including double-base propellants, pressed nitramine powders, and modified double-base propellants containing nitramine, was examined using OH-PLIF technology. The combustion process took place within a combustion chamber, and images capturing the flame at the moment of stable combustion were selected for further analysis. The distribution and production rate of OH radicals in both the double-base propellant and the nitramine-modified double-base propellant were simulated using Chemkin-17.0 software. The outcomes from both the experimental and simulation studies revealed that the concentration of OH radicals increased with a higher content of NG in the double-base propellant. In the modified double-base propellant containing RDX, the OH radical concentration decreased as the RDX content increased, with these tendencies of change aligning closely with the simulation results.