Pd‐Free Nano‐Cu/Carbon Fiber Hybrid Catalysts for Enhanced Thermal Decomposition of Ammonium Perchlorate and Composite Propellant Applications

ABSTRACT This study aimed to develop a multifunctional Pd‐free catalyst that integrates catalytic promotion of ammonium perchlorate (AP) decomposition with structural reinforcement of composite solid propellants. Nano‐Cu/carbon fiber (Cu/CF) hybrids were fabricated through a silver‐activated electroless deposition strategy using a polyethyleneimine–glutaraldehyde–silver (PEI–GA–Ag) activation system. By regulating the electroless deposition kinetics, Cu/CF hybrids with tunable Cu dispersion and surface morphology were obtained and systematically evaluated for AP decomposition and composite propellant applications. Thermal and kinetic analyses were employed to assess the catalytic effect on AP decomposition, while TGA–FTIR was used to investigate the evolution of gaseous decomposition products. The optimized CF‐3 catalyst reduced the high‐temperature decomposition temperature of AP by up to 96.5°C and markedly enhanced its heat‐release behavior. Kinetic analysis further demonstrated a substantial reduction in the activation energy of AP decomposition, while TGA–FTIR revealed accelerated evolution of gaseous products during thermal decomposition. Moreover, the Cu/CF hybrids exhibited superior catalytic performance compared with conventional Fe 2 O 3 catalysts. When incorporated into composite propellant formulations, the optimized Cu/CF catalyst improved combustion behavior and mechanical integrity, demonstrating the combined catalytic and reinforcing functions of the Cu/CF architecture. These results demonstrate the potential of Pd‐free Cu/CF hybrids as multifunctional additives for AP‐based composite propellants and provide a scalable strategy for integrating combustion catalysis with structural reinforcement.