The Effect of Process Parameters on the Structural Energetic Properties of Additively Manufactured Reactive Structures

Abstract This paper investigates the ability of an aluminum-fluoropolymer energetic material to act as a multifunctional energetic structural material (MESM). The mechanical properties of the material were determined by performing quasi-static tensile testing of 3D printed dogbones. Samples were prepared with and without particle loading, as well as with different print directions, in order to gain a fundamental understanding of how these parameters affect the mechanical properties of the material. Larger truss samples were printed in order to simulate realistic structural elements. Samples were printed in different directions and burned to determine this parameter’s effect on the combustion performance of the material. The aluminum polyvinylidene fluoride mixtures considered were shown to have viable structural capabilities as well as sufficient combustion performance. The structural energetic capabilities of the formulations considered, paired with the material’s ability to be 3D printed, could enable a number of interesting applications in the aerospace and defense industry.