Compatibility assessment of thermoplastic formulations

Prior to the large-scale preparation of any new chemical formulation an assessment of the potential reactivity between the components must be carried out. This practice, which is common to many fields including pharmaceutical science, is particularly essential in the case of energetic formulations whose chemical incompatibility may result in an unexpected and potentially explosive decomposition. The common method used to investigate incompatibility is to heat 1:1 (w/w) formulations and evaluate the variation in their thermal stability with respect to the neat, pristine explosive. The techniques used are: differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), vacuum stability and heat flow calorimetry. As trends in energetics move towards safer formulations the components are more commonly selected for their high thermal stability and low sensitivity to initiation. However, recently prepared thermoplastic formulations which incorporate a thermally stable explosive, 2,2’,4,4’,6,6’-hexanitrostilbene (HNS II), and a selection of high-melting-point thermoplastics produced anomalous results during their compatibility assessment leading to the suggestion that historical tests originally devised for less thermally stable materials, such as N,N’,N’’-trinitro-1,3,5-triazacyclohexane (RDX), may not be directly transferable to the newer generations of insensitive explosive formulations.