Safe and Scale‐up‐friendly Synthesis of TKX‐50

ABSTRACT This study presents a safe and scalable synthesis of dihydroxylammonium 5,5'‐bistetrazole‐1,1'‐diolate (TKX‐50), a high‐performance explosive with superior detonation velocity and reduced sensitivity. Traditional methods face challenges such as harsh conditions, corrosive reagents, and sensitivity of intermediates. We introduce a novel approach that replaces sensitive intermediates, eliminates corrosive HCl gas, and optimizes reaction conditions. Using a single equivalent of HCl in solution at lower temperatures, we achieve high yields of TKX‐50 under milder conditions. This method improves efficiency, scalability, and safety, facilitating broader use of TKX‐50 as a next‐generation explosive.