Electrical Solid Propellants: A Safe, Micro to Macro Propulsion Technology

In this work we developed three high performance families of plastisol solid propellants that are IM-capable and highly manufacturable, using benign processes and “green” ingredients. Highly aluminized Electric Solid Propellant (ESP) “igniterless” rocket motors have been demonstrated at 4inch diameter scale. These igniterless rocket motors use inert metal electrodes for direct ignition of the electric solid propellant, thereby eliminating the need for pyrotechnic ignition systems. A fast cook-off Insensitive Munitions test of a 4-inch diameter aluminum-cased ESP motor yielded a TypeV reaction, with no materials ejected from the burn pit. We successfully demonstrated pyrogen-free, igniterless electrically-initiated ignition of 200 lbf thrust class static tests in three separate firings conducted during the development program. In related activities, both nonmetalized minimum signature formulations and reduced-signature boron-fueled plastisol ESP compositions continue to undergo qualification testing for technology transfer applications in defense and commercial endeavors.