Three Dimensional‐Printed Aluminum/Fluorinated Ethylene Propylene Copolymer Energetic Composites With Enhanced Heat Release and Combustion Performance

The advancement of 3D printing has provided critical technical support for the application of energetic materials. However, existing energetic materials are confronted with limitations in manufacturing and practical application, as challenges in achieving high sensitivity and high loading have not been fully addressed. To address this issue, a novel ink formulation was developed using fluorinated ethylene propylene copolymer (FEP) as the oxidizer. Energetic sticks loaded with 90 wt% aluminum/fluorinated ethylene propylene (Al/FEP) were fabricated via direct ink writing (DIW) and featured an Al content gradient ranging from 40 wt% to 80 wt%, using polyvinylidene fluoride (PVDF) as the binder. The results indicate that a porous microstructure is exhibited by these sticks. The 50 wt% Al/50 wt% FEP/PVDF (AFP‐50) energetic stick exhibited optimal combustion performance under anaerobic conditions, characterized by a peak pressure of 472 kPa, a pressurization rate of 49.0 kPa/ms, a burning rate of 68 mm/s, and a combustion heat of 8410 J/g. Notably,compared to Al/PTFE/PVDF, which exhibits superior combustion and heat‐release performance, the AFP‐50 energetic stick exhibited an 8.5% increase in combustion heat and a 41.4% increase in burning rate. Moreover, the energetic stick exhibited different exothermic combustion reaction mechanisms under different atmospheric conditions. This study expands the application prospects of Al/high‐fluorine polymer composites in microenergetic devices.