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 50 wt% 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 23 cm s⁻¹ for loadings of 16.7, 30, and 50 wt% 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.