Programmable multiscale energy release in synergistic energetic composites with three dimensional printed architectures
Year: 2026
Type: article
Abstract: Metastable intermolecular composites (MICs) and energetic materials (EMs) exhibit unparalleled energy release characteristics for propulsion and detonation systems. This work presents an innovative acoustic resonance-assisted integration and direct ink writing (DIW) 3D printing strategy to fabricate Al/Ti/CuO-HMX (ATC-HMX) composites with programmable architectures (filamentary and core-shell structures). Comprehensive characterization demonstrates that ATC particles uniformly coat HMX surfaces, forming dense composites. The 40wt% ATC formulation reduces HMX decomposition temperature by 6.51°C while achieving remarkable performance enhancements: 99.51 KPa peak pressure (+60.45% vs HMX), 838.01 kPa/s pressurization rate (+2220.94%), and 7331 J/g heat release (+23.92%) in confined systems. Open combustion exhibits self-sustained flames (1778-2030°C) with deflagration-to-detonation transition (DDT) under geometric constraints. Laser-driven impacts generate >900 m/s shockwaves and plasma intensity proportional to ATC content. 3D-printed 40ATC-60HMX filaments display 18.2 mm/s burn rates and dual-peak "secondary pressurization" (112.34 kPa), while core-shell architectures produce 1827.2°C fireballs (1.5 m diameter) with 2.26/0.47 MPa overpressures at 0.33/0.66 m. The work elucidates the ATC-HMX synergy mechanism under multiscale reactive conditions and establishes a controllable synthesis platform enabling structure-performance tailored MICs/EMs, bridging advanced additive manufacturing with tailored energetic performance. The strategy unlocks transformative potential for next-generation propulsion and detonation systems.
Source: Nature Communications
Language: English
Subfield: Mechanics of Materials
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $6,990
Awards: G4022112405, G7461582237
OpenAlex ID: W7140504439