Damage analysis of solid propellants with default defects based on macro-microscopic approach

• Microstructures and default defects of propellants are identified and quantified based on micro CT measurements. • Microscopic damage analysis uses representative volume elements integrated with cohesive zone theory. • A novel damage model, calibrated with microscopic damage, demonstrates satisfactory predictive capabilities. Solid Rocket Motors (SRMs) rely on solid propellants, directly impacting the energy capacity of launch vehicles. High energy density material (HEDM) propellant exhibits superior energy density owing to the incorporation of a substantial quantity of energetic particles. However, the elevated particle fill ratio makes the formation of pores more prevalent during the manufacturing process of propellants. These pores, representing default defects, are indispensable factors in the investigation of mechanical properties of propellants. This study investigated default defects effects on HEDM propellants, analyzing both microscopic and macroscopic perspectives. Utilizing micro-CT imaging, the microstructure and default defects were characterized. Subsequently, using the cohesive zone model (CZM), microscopic damage evolution was depicted with the representative volume element (RVE) model, allowing in-depth analysis. Furthermore, a damage constitutive model, based on microscopic damage, was developed, with its softening function calibrated using microscopic damage evolution characteristics. Implemented into ABAQUS via user-defined material subroutine (UMAT), this model enabled the prediction of the mechanical response of HEDM propellants with different defects. The results demonstrate that the developed model accurately predicts the mechanical responses of HEDM propellants with different defects, showcasing the potential of macro-microscopic approaches in analyzing propellants with default defects.