Effect of NCO/OH ratio and binder content with micro-AP on HTPB/AP/Al-based propellants mechanical properties

This study evaluates the ratio of Toluene di-isocyanate (TDI) functional group isocyanate (NCO) to the binder functional hydroxyl group (OH) in HTPB/AP/Al-based propellants on their mechanical properties, flow rate, and viscosity to determine the limitations of NCO/OH in the composition of solid propellants. The propellants consisted of hydroxyl-terminated polybutadiene (HTPB) polyurethane (PU), aluminum (Al) and tri-modal ammonium perchlorate (AP). The tri-modal AP consisted of 30% of coarse AP, 30% of medium AP, and 8% of fine AP. The ratio of NCO/OH varies from 0.73 to 0.85, with two binder percentages of 10.5% and 12%. An increase in NCO/OH ratio with 10.5% binder provided 20%, 95%, and 8 to 9% increments in UTS, modulus, and hardness, respectively. However, the propellant elongation, density, and flow rate decreased by 170%, 0.2%, and 11-12%, respectively. Viscosity increased 20% based on initial hour reading. The 12% binder provides 27%, 47%, and 5~6% an increment of UTS, modulus and hardness respectively. However, the propellant elongation, density, and flow rate decreased by 47 %, 0.17% and 27%, respectively. The viscosity increased 30% based on initial hour reading. This study suggests the NCO/OH value of 0.77 and 10.5~11% binder content in propellant based on the mechanical properties, flow rate, and viscosity for better processing and pot life.