Electrospray Deposition of Energetic Polymer Nanocomposites with High Mass Particle Loadings: A Prelude to 3D Printing of Rocket Motors

One of the challenges in the use of energetic nanoparticles within a polymer matrix is the difficulty in processing by traditional mixing methods. In this paper, electrospray deposition is employed to create high loadings of aluminum nanoparticles (Al-NPs) in polyvinylidene fluoride (PVDF) reactive composite films. The deposited films containing up to 50wt% Al are found to be crack free and mechanically flexible. Thermochemical behavior characterized by thermogravimetric (TG) and differential scanning calorimetry (DSC) analysis shows that the addition of Al-NPs sharply reduces the onset decomposition temperature due to a pre-ignition reaction occurring in the film. The combustion propagation velocity in air at three different mass loading of Al-NPs shows burning rates of 5, 16, and 23cms(-1) for loadings of 16.7, 30, and 50wt% Al-NPs. The results suggest electrospray deposition as a direct approach to make bulk polymer composites containing high metal particle mass loading and may be a prelude to 3D printing of rocket motors.