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Energetic materials in 3D: an in-depth exploration of additive manufacturing techniques

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Abstract

Recently, because of the complex international situation and combat environment in the future, the development and application of new concept weapons have raised higher performance requirements for manufacturing technologies. However, at present, most weapons are still prepared using traditional charging methods (cast curing, pressure casting, and melt casting), which require subtractive manufacturing (SM) treatments before use. At present, the demand for weapon products is shifting towards reactive micro structures, high preparation efficiency, miniaturization, and controllable energy release. Besides, the modern “energetic-on-a-chip” trend was expected to reduce size and cost while increasing safety and maintaining performance. In this case, the traditional charging methods were not preferred due to their inherent drawbacks, such as being limited to the model, requiring long solvent drying times and recycling required and pores/cracks caused by the shrinkage of slurry, and so on. Therefore, it is necessary to innovate the processing and manufacturing technology of weapons and address the boundaries of existing charging methods, and this will enable the precise customization of high-quality energetic materials and avoid many defects. Additive manufacturing (AM), or 3D printing technology, has been booming recently. The application of additive manufacturing technology in the field of energetic materials (EMs) can promote the innovation of manufacturing technology for EMs and regulate the microstructure. Additionally, 3D printing technology can break through the existing design and development mode, expand explosive charging technology, and enable the distribution of different types of explosives and explosive density in a specific space area. Besides, 3D printing can fabricate “reactive microstructures” (RMS), which offer a deeper understanding of the EMs’ combustion and detonation phenomena at the micro- and nanoscale. Thus, the explosive/propellant grains with multiple damage modes can be designed and manufactured. This paper aims to summarize the current progress in the 3D printing of EMs, analyze the corresponding mechanisms, and provide guidance for future research.

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Acknowledgements

The authors acknowledge the support from the National Special Superfine Powder Engineering Technology Research Center.

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Authors and Affiliations

  1. Shandong Nonmetal Materials Research Institute, **an, 250031, China

    Hu-zeng Zong

  2. National Special Superfine Powder Engineering Technology Research Center, Nan**g University of Science and Technology, Nan**g, 210094, China

    Su-wei Wang, Hao Ren, Ga-zi Hao, Lei **ao & Wei Jiang

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  1. Hu-zeng Zong
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  2. Su-wei Wang
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  3. Hao Ren
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  4. Ga-zi Hao
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  5. Lei **ao
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  6. Wei Jiang
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Correspondence to Lei **ao or Wei Jiang.

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Highlights

The process of 3D printing energetic materials is elaborated.

The printability of energetic materials was analyzed.

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Zong, Hz., Wang, Sw., Ren, H. et al. Energetic materials in 3D: an in-depth exploration of additive manufacturing techniques. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13937-6

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