Modified Micro-Emulsion Synthesis of Highly Dispersed Al/PVDF Composites with Enhanced Combustion Properties

Energetic composites of reactive metals and polymers have important applications ranging from pyrotechnics to solid-propellant rockets and solid fuel ramjets. Composites of aluminum (Al) and fluoropolymers (e.g., polyvinylidene fluoride (PVDF)) are of particular interest due to the high energy density of Al and the high oxidizing potential of fluoropolymers. However, the agglomeration of Al particles within the fluoropolymer matrix reduces their ignition and combustion performance. Thus, improving the dispersion of Al particles within the polymer matrix is essential for achieving high-performance energetic composites. Here, this study combines the Al particle surface functionalization and their pre-dispersion in a micro-emulsion prior to their incorporation into the polymer matrix to achieve well dispersed Al/PVDF composites, which refers to as the modified micro-emulsion method. The enhanced dispersion of Al particles in Al/PVDF composites prepared by the modified micro-emulsion method is confirmed by optical images, scanning electron microscopy, and energy dispersive spectroscopy. Shorter ignition times and higher combustion reactivity and efficiency are achieved for the Al/PVDF composites prepared by the modified micro-emulsion method compared to those prepared by mechanical mixing with and without surface functionalization.