A Bionic Peristaltic Process for Enhanced Powder Dispersion in Energetic High-Solid-Loading Slurries

Abstract This study introduces a paddle-less bionic peristaltic mixing process, inspired by intestinal biomechanics, for enhanced powder dispersion in energetic high-solid-loading slurries (80% solids). Periodic elastic conduit compression induces low-shear vortices, substantially reducing energy consumption compared with conventional mechanical stirring in solid propellant preparation. ANSYS Fluent simulations employing dynamic meshing and the Navier–Stokes equations demonstrate bidirectional flows and effective phase homogenization, achieving high-density uniformity after 300 s. Experiments using a NaCl/Al/HTPB solid-propellant simulant identified the optimal operating parameters as an extrusion duration of 3 s, an air pressure of 0.6 MPa, four peristaltic segments, and an intersegment spacing of 5 mm. Under these conditions, the mean density across the five axial sections was 1.513 g·cm–3, and the axial-density standard deviation was 0.016 g·cm–3, corresponding to an approximately 58% improvement in spatial uniformity relative to the baseline condition. Scanning electron microscopy confirms uniform particle coating and grading. This low-shear, energy-efficient method provides an innovative approach for solid propellant mixing and holds broad potential for other high-solid powder composites in pharmaceuticals and ceramics.