Research Progress of Multi-Dimensional Catalysts in Regulating Thermal Decomposition Behavior of Ammonium Perchlorate and Enhancing Combustion Performance of Composite Solid Propellant

Abstract

Ammonium perchlorate (AP) is a commonly used oxidizer in composite solid propellants, and its thermal decomposition characteristics directly determine key propellant performances such as ignition and burning rate. However, AP faces challenges including high decomposition temperature, long ignition delay, and unstable combustion. To address these issues, researchers worldwide have dedicated efforts to developing efficient, stable, and green catalysts. This review systematically summarizes the catalytic mechanisms and performances of various catalysts ranging from zero-dimensional to three-dimensional. 0D catalysts, such as nanometal powders and metal oxides, reduce AP decomposition temperature and enhance heat release via their high specific surface area but suffer from poor dispersion and easy agglomeration. 1D catalysts inhibit agglomeration and improve catalytic kinetics by constructing continuous electron/ion transport channels. 2D catalysts, particularly MXene-based materials, exhibit outstanding performance, enabling a reduction of over 200 °C in AP’s high-temperature decomposition peak and more than a 2-fold increase in heat release. 3D catalysts achieve efficient mass transfer and conversion through hierarchical pores and other structural features. Catalysts significantly improve the ignition characteristics and steady combustion performance of propellants. Nevertheless, engineering bottlenecks including large-scale preparation and dispersion stability remain to be overcome. Future research should focus on green synthesis, structural optimization, and other directions to construct advanced catalytic systems, providing theoretical support for the development of high-performance and environmentally friendly solid propellants.