Composite solid propellant compositions and methods of production and use thereof

1 . A method of producing a solid propellant grain, the method comprising the steps of:

(1) combining, either simultaneously or wholly or partially sequentially, a resin binder, aluminum powder, and copper chromite to form a mixture;

(2) adding a plasticizer to the mixture;

(3) degassing the mixture;

(4) adding, in a sequential order, ammonium perchlorate at three different particle sizes to the mixture in substantially equal amounts, wherein the average particle size of the three particle sizes is in a range of from about 199 μm to about 261 μm, and wherein a smallest particle size is added last;

(5) degassing the mixture;

(6) adding a curative agent to the mixture; and

(7) disposing the mixture into a casting liner and allowing the mixture to cure and harden to form a solid propellant.

2 . The method of claim 1 , further comprising the step of:

(8) cutting the solid propellant into at least one grain.

3 . The method of claim 1 , wherein the solid propellant comprises:

the trimodal mix of ammonium perchlorate at a total concentration in a range of from about 70 wt % to about 80 wt %;

aluminum powder at a concentration in a range of from about 0.01 wt % to about 10 wt %;

the resin binder at a concentration in a range of from about 10 wt % to about 15 wt %;

copper chromite at a concentration in a range of from about 0.05 wt % to about 0.2 wt %;

plasticizer at a concentration in a range of from about 1 wt % to about 5 wt %; and

curative agent at a concentration in a range of from about 1 wt % to about 5 wt %.

4 . The method of claim 1 , wherein at least one of:

the resin binder is hydroxyl-terminated polybutadiene resin (HTPB) infused with tepanol;

the plasticizer comprises Dioctyl adipate (DOA);

the curative agent is selected from the group consisting of MDI and IDPI; and/or

step (2) further comprises adding a bonding agent to the mixture.