Nano-sized boron composites energetic materials: Preparation, combustion and mechanism

• Comprehensive summary and comparison of nano-boron (nB) composites energetic materials (CEMs) preparation methods with advantages and disadvantages • A comparison with other B powder modification methods highlights the exceptional ignition and combustion performance of nB CEMs. • Fluorinated compounds and metals optimize combustion mechanisms • Challenges and future prospects for scalable, safe, and efficient applications Nano-sized boron (nB)-based composite energetic materials (CEMs) are an emerging class of high-energy-density fuels with excellent combustion performance, offering broad potential applications in space propulsion and explosives. In this paper, we review the various preparation techniques for nB-based CEMs (comparing their respective advantages and limitations) and discuss the combustion characteristics and reaction mechanisms of these materials, while also surveying current development trends and future challenges. Recent findings show that incorporating nB significantly improves the ignition characteristics, burning rates, and overall energy release efficiency of B-based energetic formulations. In particular, nB-based composites exhibit faster reaction kinetics, higher energy release rates, and greater gas generation than their micro-sized boron (μB) counterparts. These enhancements underscore the promise of nB-based CEMs for next-generation propellants, explosives, and pyrotechnics, and existing research has already laid a solid foundation for further progress in designing such advanced energetic systems.