The polyurethane elastomer-based PBX with excellent cyclic manufacturing performance

Plastic-bonded explosives (PBXs) have been subjected to intensive research worldwide due to their superior energy release efficiency and insensitivity characteristics. However, thermoset PBXs face several challenges, including long curing times, significant batch-to-batch variation, and difficulties in recycling residual materials. To address these issues, the interface interactions between thermoplastic polyurethane (TPU) and solid components, compatibility with plasticizers, and compatibility with energetic components (such as HMX and Al) were analyzed, leading to the development of a PBX with TPU as the binder. Further characterization of the microstructure and macroscopic mechanical properties of the thermoplastic PBXs revealed that their post-molding charge structure is dense, exhibiting mechanical properties comparable to those of thermosetting PBXs. More importantly, during five consecutive repeated manufacturing processes, the composition and mechanical property consistency of the thermoplastic PBXs were highly consistent, with the maximum deviation in mechanical properties being only 5.6%. Thermoplastic PBXs demonstrate excellent reproducibility and recyclability, offering unique advantages in residual material recovery and circular utilization.