Preparation of Inverse-Loaded MWCNTs@Fe2O3 Composites and Their Impact on Glycidyl Azide Polymer-Based Energetic Thermoplastic Elastomer

As a novel carbon material, multi-walled carbon nanotubes (MWCNTs) have attracted significant research interest in energetic applications due to their high aspect ratio and exceptional physicochemical properties. However, their inherent structural characteristics and poor dispersion severely limit their practical utilization in solid propellant formulations. To address these challenges, this study developed an innovative reverse-engineering strategy that precisely confines MWCNTs within a three-dimensional Fe2O3 gel framework through a controllable sol-gel process followed by low-temperature calcination. This advanced material architecture not only overcomes the traditional limitations of MWCNTs but also creates abundant Fe-C interfacial sites that synergistically catalyze the thermal decomposition of glycidyl azide polymer-based energetic thermoplastic elastomer (GAP-ETPE). Systematic characterization reveals that the MWCNTs@Fe2O3 nanocomposite delivers exceptional catalytic performance for azido group decomposition, achieving a >200% enhancement in decomposition rate compared to physical mixtures while simultaneously improving the mechanical strength of GAP-ETPE-based propellants by 15–20%. More importantly, this work provides fundamental insights into the rational design of advanced carbon-based nanocomposites for next-generation energetic materials, opening new avenues for the application of nanocarbons in propulsion systems.