High-Throughput Fabrication of B/Fe2O3/F2603 MIC composite microspheres via microchannel technology

•Combination of molecular dynamics simulations and high-throughput microchannel technologies.•Synthesis of spherical B/Fe2O3@F2603 composite microspheres with uniformity and high sphericity.•Presentation of a high-efficiency, high-precision manufacturing process for composite microspheres with applications in national defense and aerospace. Boron (B)-based Metastable Intermolecular Composites (MIC) exhibits prominent advantages in the fields of weaponry and aerospace due to its significant high mass heat value. However, the dense oxide layer on the B surface and the inhomogeneous mixing of different components pose significant challenges for the practical application of B-based MIC. Thus, exploring the construction of microspheres with high uniformity and excellent comprehensive performance has become a promising yet challenging solution. This study involved the effective synthesis of B-based composite microspheres using a high-throughput microchannel methodology combined with molecular dynamics (MD) technology. Firstly, MD simulations were employed to successfully select the fluorinated polymer F2603 as a suitable binder, with an optimal usage amount determined to be 10%. Experimental results demonstrate the successful synthesis of B/Fe2O3@F2603 composite microspheres with a uniform spherical structure using high-throughput microchannel technology. The thermal study data indicates that the catalytic effect of Fe2O3 is optimum when its content is 5%. It leads to a large decrease in the exothermic peak temperature of B from 770℃ to 660℃, while also demonstrating outstanding combustion performance. Furthermore, it is revealed that the significant catalytic effect can be attributable to the bidirectional transfer function of Fe2O3 at both the interface between B-B2O3, as well as the contact between B2O3-air. In addition, the composite microspheres demonstrate good fluidity, excellent hydrophobic properties, and outstanding mechanical strength because of the inclusion of F2603 and its high level of sphericity. The research unveils the significant potential of microchannel technology in efficiently and safely fabricating of MIC with exceptional performance, thereby opening new avenues and perspectives to produce composite energetic materials.