TY - JOUR
T1 - 3D printing complex structure of energetic charges with binder jetting & direct ink writing jointly for flexible combustion
AU - Xin, Haoyue
AU - Chen, Yongjin
AU - Wu, Xinzhou
AU - Deng, Yucheng
AU - Ren, Hui
N1 - Publisher Copyright:
© 2025 Elsevier Ltd
PY - 2026/1
Y1 - 2026/1
N2 - Additive manufacturing technology enables flexible customization and efficient processing of complex configurations. This study designed a composite energetic charge with a boron/potassium nitrate (B/KNO3) outer shell for low ignition threshold and an aluminum/ammonium perchlorate (Al/AP) core for high energy release, fabricated through direct ink writing (DIW) and binder jet 3D printing (BJ3DP) process. The manufacturing parameters were systematically optimized, with BJ3DP powder-binder ratios determined through powder dispersion and binder adhesion analysis and DIW ink formulations characterized by rheological measurements. The test results of the printed samples show that the strips have uniform distribution of the components, and can be stably burned. The combustion reaction of B/KNO3 is rapid and the rate of pressure rise is fast, while the combustion calorific value and combustion temperature of Al/AP are higher, and the total energy is higher than that of B/KNO3 in the case of sufficient oxygen. MATLAB/Simulink software was used to establish a constant volume combustion model, the simulation results show that optimal 1:9 shell-to-core mass ratio that maximizes energy output effect, and the ignition heat transfer process of the composite structure was revealed through combustion test.
AB - Additive manufacturing technology enables flexible customization and efficient processing of complex configurations. This study designed a composite energetic charge with a boron/potassium nitrate (B/KNO3) outer shell for low ignition threshold and an aluminum/ammonium perchlorate (Al/AP) core for high energy release, fabricated through direct ink writing (DIW) and binder jet 3D printing (BJ3DP) process. The manufacturing parameters were systematically optimized, with BJ3DP powder-binder ratios determined through powder dispersion and binder adhesion analysis and DIW ink formulations characterized by rheological measurements. The test results of the printed samples show that the strips have uniform distribution of the components, and can be stably burned. The combustion reaction of B/KNO3 is rapid and the rate of pressure rise is fast, while the combustion calorific value and combustion temperature of Al/AP are higher, and the total energy is higher than that of B/KNO3 in the case of sufficient oxygen. MATLAB/Simulink software was used to establish a constant volume combustion model, the simulation results show that optimal 1:9 shell-to-core mass ratio that maximizes energy output effect, and the ignition heat transfer process of the composite structure was revealed through combustion test.
KW - Additive manufacturing
KW - Binder jetting 3D printing
KW - Complex structure
KW - Direct ink writing
KW - Energetic charge
UR - https://www.scopus.com/pages/publications/105020804495
U2 - 10.1016/j.icheatmasstransfer.2025.109996
DO - 10.1016/j.icheatmasstransfer.2025.109996
M3 - Article
AN - SCOPUS:105020804495
SN - 0735-1933
VL - 170
JO - International Communications in Heat and Mass Transfer
JF - International Communications in Heat and Mass Transfer
M1 - 109996
ER -