Superior Energy Release of Ammonium Perchlorate Composites by Embedding Heterostructured Carbon Nanotube/Tricobalt Tetraoxide Thermal Conduction Pathways

To address the inherent challenge of low reaction efficiency arising from interfacial thermal resistance in composite energetic materials, this study proposes a synergistic strategy integrating engineered thermal conduction pathways with precision catalysis for achieving high-efficiency energy release in ammonium perchlorate (AP). Heterostructured carbon nanotube (CNT)/Co₃O₄ was synthesized via in situ growth of Co₃O₄ nanoclusters on CNTs, followed by embedding onto the AP surface through spray drying-suspension coating technology. Comprehensive characterization confirmed the effective anchoring, uniform distribution, and interfacial interactions of Co₃O₄. With only 1 wt% CNT/Co₃O₄ loading, the high-temperature decomposition peak temperature of AP was dramatically reduced from 450.9 °C (pristine AP) to 310.7 °C, accompanied by a 24.3% enhancement in heat release and a substantial 64.8% reduction in activation energy. Combustion tests revealed a 72.6% increase in flame radiation intensity and a 2.3-fold acceleration in pressurization rate for AP@CNT/Co mixing with aluminum. Mechanistic studies elucidate a tripartite synergy: (a) CNT-derived thermal conduction pathways elevate thermal conductivity, (b) Co₃O₄ facilitates proton/electron transfer and drives the oxidation of gaseous products toward higher-valent nitrogen oxides, and (c) surface microporosity accelerates heat/mass diffusion. This concerted action enables focused, rapid, and efficient energy release from AP. This work establishes a generic interfacial engineering paradigm for enhancing energy release efficiency in composite energetic materials. © 2025 Ruixuan Xu et al.