Targeted modulation of Al-Mg-B and Al-Ti-V ternary alloys for enhanced combustion and suppressed agglomeration in composite propellants

Directionally modulated Al-Mg-B/Al-Ti-V alloys enable dual-mode synergy. • Lower ignition thresholds, boost heat release, and enhance motor safety. • Agglomerate size reduced by 45.8% (AMB) and 54.8% (ATV), boosting energy release efficiency. • “On-demand” alloy design delivers predictable optimization for tailored fuels. Low energy release efficiency due to aluminum agglomeration remains a critical bottleneck limiting the performance of composite propellants. This study employs two directionally modulated ternary alloys, Al-Mg-B and Al-Ti-V, to optimize the full-cycle performance of HTPB composite propellants via multi-element synergy. Optimal alloy ratios are identified via combustion experiments. The selected alloys are subjected to thermal oxidation analysis, and the corresponding composite propellants are prepared. Systematic tests evaluate ignition, combustion, agglomeration, and products under high pressure. Results indicate that ternary alloy modification promotes efficient ignition, significantly increases combustion heat release, and markedly reduces pressure sensitivity. Specifically, the modification suppresses agglomeration (mean particle size reductions of 45.8% and 54.8%, respectively), thereby improving energy-release efficiency. Further investigation clarifies the mechanisms governing the behavior of Al-Mg-B and Al-Ti-V in composite propellants. These findings suggest that directionally modulated ternary alloys offer a viable strategy for simultaneously enhancing energy release and potentially improving motor operational safety.