Aluminum behavior—accumulation, agglomeration and ignition—is studied in a unique, wide-distribution, ammonium perchlorate/hydroxyl-terminated polybutadiene (AP/HTPB) propellant formulation that results in low Al agglomeration, even at low pressures (1-30 atm). Variations in formulation—such as fine-AP/binder ratio, Al particle size, Al loading, coarse-AP size—are also examined. A fuel-rich, oxygenated binder matrix highly loaded with fine (2-µm) AP (FAP) at 75/25:FAP/binder (by mass) is found to have premixed flame conditions that produce minimal agglomeration (without ignition) of 15-µm Al. Coarse AP (CAP) is added to the system in the form of either particles (200 or 400 µm) or pressed-AP laminates (simulated CAP). In the 2-D laminate system the CAP/oxyfuel-matrix flame structure is seen to be similar to that previously described for non-aluminized laminates with split (diffusion) and merged (partially-premixed) flame regimes, depending on pressure and fuel-matrix thickness. Both laminate and particulate systems show that with CAP present, Al can agglomerate more extensively on CAP via lateral surface migration from fuel matrix to the CAP region. The particulate CAP system also shows that Al can accumulate/agglomerate via settling on CAP from above (in the direction of burning). Both systems, but more clearly the 2-D laminates, show that with CAP present, Al is ignited by the outer CAP/fuel-matrix canopy flames. Thus, a propellant formulation is proposed for reducing overall Al agglomeration through intrinsically reduced agglomeration in the fuel-matrix and a reduced number of CAP-particle agglomerates via higher FAP/CAP ratio.
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