Structure‐Controlled FOX‐7 Microspheres: Enhanced Combustion Performance and Energy Release Efficiency

ABSTRACT In the realm of energy‐containing material modification, sphericalized granulation markedly enhances the processing and application properties of explosives. This article employs droplet microfluidic technology (DMT) to fabricate FOX‐7 microspheres with regular morphology, uniform elemental distribution, high roundness, and commendable loading performance in suspension form using fluoroelastomer (F 2602 ) and nitrocellulose (NC) as a composite binder. The study investigates the impact of varying binder ratios and concentrations on the microspheres’ morphology and size. Further analysis includes dispersion, crystal structure, thermal properties, mechanical sensitivity, and combustion characteristics. The findings indicate that adjusting the composite binder ratio regulates the microstructure and size of FOX‐7 microspheres, transitioning from erythrocyte‐like to high sphericity. Compared to raw FOX‐7, the microspheres exhibit a porous structure with enhanced dispersion, retaining the crystal and chemical structure of the raw material. The thermal decomposition of the microspheres is accelerated, and their combustion performance is superior, enhancing energy release efficiency and offering improved safety performance over the raw material. This preparation method is straightforward and efficient, offering a versatile and environment‐friendly technical approach for the modification design of energy‐containing materials.