The safe storage time for double base propellant (DBP or DB propellant) with stabilizers could usually be calculated to be greater than 40 years. However, the actual service life is far below that, which is largely caused by the decline of propellant mechanical performance. In this work polytetrafluoroethylene (PTFE) was introduced into the double base propellant formula as an additive. The tensile properties of this propellant before and after artificial aging were determined. The evaporation and diffusion characteristics of nitroglycerin (NG) in propellant were evaluated by thermogravimetry analysis (TGA). The results showed that mechanical properties of propellant were improved due to PTFE, especially for elongation at −40 °C, which was greatly increased by 115%. Moreover, the results of TGA showed that NG migration was reduced due to PTFE, which delayed the decline of propellant mechanical performance during aging. The reduction in elongation at −40 °C caused by aging was decreased by 68.5% for PTFE modified DBP. Enhanced mechanical properties and reduced NG migration could potentially prolong propellant service life.

The relatively poor mechanical properties of extruded modified double base (EMDB) propellants limit their range of applications. To overcome these drawbacks, a novel method was proposed to introduce glycidyl azide polymer-based energetic thermoplastic elastomers (GAP-ETPE) with bonding groups into the propellant adhesive. The influence of the molecular structure of three kinds of elastomers on the mechanical properties of the resultant propellant was analyzed. It was found that the mechanical properties of the propellant with 3% CBA-ETPE (a type of GAP-ETPE that features chain extensions using N-(2-Cyanoethyl) diethanolamine and 1,4-butanediol) were improved at both 50 °C and −40 °C compared to a control propellant without GAP-ETPE. The elongation and impact strength of the propellant at −40 °C were 7.49% and 6.58 MPa, respectively, while the impact strength and maximum tensile strength of the propellant at 50 °C reached 21.1 MPa and 1.19 MPa, respectively. In addition, all three types of GAP-ETPE improved the safety of EMDB propellants. The friction sensitivity of the propellant with 3% CBA-ETPE was found to be 0%, and its characteristic drop height H₅₀ was found to be 39.0 cm; 126% higher than the traditional EMDB propellant. These results provide guidance for studies aiming to optimize the performance of EMDB propellants.

Al-based nanocomposite energetic materials have broad application prospects in explosives and propellants, owing to their excellent energy release efficiency. However, their insufficient reliability, poor stability, and difficulty of formation limit their practical application. This study employed self-assembly using a hydrophilic polymer polyvinylpyrrolidone (PVP) together with nano-aluminum powder (Al), copper oxide (CuO), and ammonium perchlorate (AP) to obtain high-strength and high-activity composite micrometer-sized microspheres. The influence of PVP concentration on the mechanical behavior of Al/AP composite microspheres was systematically investigated, and Al was replaced with ultrasonically dispersed Al/CuO to explore the mechanism of action of PVP in the system and the catalytic behavior of CuO. PVP significantly enhanced the interfacial bonding strength. The Al/AP/5%PVP microspheres achieved a strength of 8.4 MPa under 40% compressive strain, representing a 365% increase relative to Al/AP. The Al/CuO/AP/5%PVP microspheres achieved a strength of 10.2 MPa, representing a 309% increase relative to Al/CuO. The mechanical properties of the composite microspheres were improved by more than threefold, and their thermal reactivities were also higher. This study provides a new method for the controlled preparation of high-strength, high-activity, micrometer-sized energetic microspheres. These materials are expected to be applied in composite solid propellants to enhance their combustion efficiency.