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Abstract

This research employs the sphere packing volume (SPV) model to optimize the density of composite propellants thereby enhancing rocket performance. We systematically varied the diameters of spherical ammonium perchlorate (AP) particles (50 and 400 µm) and aluminum powder (Al) particles (10 and 30 µm). These particles were incorporated at an ideal AP:Al ratio of 4:1 into a matrix of hydroxyl-terminated polybutadiene and toluene diisocyanate. By adjusting the AP ratio for each Al particle size and considering theoretical and tap densities, we precisely calculated the SPV value for each composition. The composition with the highest SPV value yielded remarkable results. This optimal sample exhibited a combustion energy of 7.46 J/g, a specific impulse of 278.70 seconds, and a Shore A hardness of 90.88. Its theoretical density reached 1.75 g/cm3, closely matching the actual density of 1.74 g/cm3. This resulted in an impressive theore-tical/actual density ratio of 99.30% indicating exceptional agreement between predicted and experimental values. The near-perfect match between theoretical and actual densities in our experiments underscores the effectiveness of the SPV model in refining composite propellant formulation theory enabling us to maximize packing density through strategic propellant selection.

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