Synergistic Energetic Composites: 3D-Printed Al/Ti/CuO-HMX Architectures with Programmable Multiscale Energy Release

Abstract Metastable intermolecular composites (MICs) and energetic materials (EMs) exhibit unparalleled energy release characteristics for propulsion and detonation systems. This work presents an innovative acoustic resonance-assisted integration and direct ink writing (DIW) 3D printing strategy to fabricate Al/Ti/CuO-HMX (ATC-HMX) composites with programmable architectures (filamentary and core-shell structures). Comprehensive characterization demonstrates that ATC particles uniformly coat HMX surfaces, forming dense composites. The 40wt% ATC formulation reduces HMX decomposition temperature by 6.51°C while achieving remarkable performance enhancements: 99.51 KPa peak pressure (+60.45% vs HMX), 838.01 kPa/s pressurization rate (+2220.94%), and 7331 J/g heat release (+23.92%) in confined systems. Open combustion exhibits self-sustained flames (1778-2030°C) with deflagration-to-detonation transition (DDT) under geometric constraints. Laser-driven impacts generate >900 m/s shockwaves and plasma intensity proportional to ATC content. 3D-printed 40ATC-60HMX filaments display 18.2 mm/s burn rates and dual-peak "secondary pressurization" (112.34 kPa), while core-shell architectures produce 1827.2°C fireballs (1.5 m diameter) with 2.26/0.47 MPa overpressures at 0.33/0.66 m. The work elucidates the ATC-HMX synergy mechanism under multiscale reactive conditions and establishes a controllable synthesis platform enabling structure-performance tailored MICs/EMs, bridging advanced additive manufacturing with tailored energetic performance. The strategy unlocks transformative potential for next-generation propulsion and detonation systems.