Performance Optimized Hierarchical Microstructure Propellant for Future Small Interceptor Rocket Motors

Future interceptors would benefit from advanced propulsion capabilities, with higher performance in smaller, volume-constrained systems. Innovative propellant chemistry is needed to enable substantially greater performance in smaller packages. One factor limiting the maximum performance achievable in modern solid propellants is the slow ignition and combustion of the propellant’s metal fuel particles, typically aluminum. Problems due to the slow reaction of aluminum are exacerbated in small rocket motors. Incomplete aluminum combustion due to short residence time in small combustors causes significant performance loss. Therefore, the theoretical maximum performance of metal-loaded fuels is unattainable with existing technology. Helicon has developed a new class of polymer-bonded aluminum fuels to dramatically increase the specific impulse and burning rate capabilities of future propellants. Helicon’s technology fundamentally transforms the aluminum combustion mechanism. Using a novel, scalable in situ nanocomposite synthesis process, Helicon produces high-energy composites with near molecular-level intermixing of the aluminum fuel and polymer binders. The Phase I project results included key successes that demonstrated the feasibility of this technology. In Phase II, Helicon will scale up material production, continue propellant formulation development, analytically evaluate the performance enhancements gained at the component and system levels, and develop a roadmap and insertion point for technology transition. Approved for Public Release 19-MDA-10203 (4 Sep 19)