Preparation and Characterization of Pour‐Casting Red Phosphorus Smoke Agents with HTPB as Binder

The main aim of this study is to develop the vacuum pour‐casting process of the red phosphorus smoke agents. The typical composition of MK 58 marine location marker prepared by tamp‐casting process is red phosphorus (RP)/magnesium (Mg)/manganese dioxide (MnO2)/zinc oxide (ZnO)/epoxy resin (ER), which was selected as the original formula. Epoxy resin (ER) was replaced by hydroxyl terminated polybutadiene (HTPB) as the binder. First of all, simultaneous differential scanning calorimetry‐thermogravimetric analysis (STA DSC‐TGA) and vacuum stability tester (VST) were used to analyze the thermochemical characteristics, stability and chemical compatibility of the formula. Afterwards, Taguchi's experimental design method was used to design nine experimental conditions by way of orthogonal array with four control factors and three levels, and the scaled‐down smoke pellets were prepared using the vacuum pour‐casting method. The combustion phenomenon of these smoke pellets was recorded by the visual‐image capture system, and the flame temperature was measured by the temperature measurement system. The burning rate was chosen as the quality characteristic to analyze the optimal parameter combination of minimum burning rate. In addition, scanning electron microscopy coupled with energy dispersive spectroscopy (SEM‐EDS), tensile testing machine (TTM) and hardness tester (HT) were employed to observe the uniformity of the composition distribution in the pellet and to measure the mechanical strength and hardness of the pellets. Smoke density test chamber (SDTC) was used to measure the specific optical density of smoke generated by RP smoke agent. Finally, the operating conditions of the optimal parameter combination determined by Taguchi method were used to prepare the full‐size smoke candle, and its burning performance was verified and the feasibility of the vacuum pour‐casting technology was evaluated. The experimental results indicated that the optimal combination of parameters was the RP mixture/HTPB mass ratio of 84 : 16, the NCO/OH ratio of IPDI to HTPB (R value) of 1.6, the additional DOA of 4.5 wt % and the curing temperature of 50 °C. The prepared scaled‐down smoke pellets had good stability, chemical compatibility, hardness, mechanical properties and burning smoke density. In addition, the burning time and performance of the full‐size smoke candles prepared by vacuum pour‐casting technology also met the requirements.