There is an urgent need for developing and using an accurate, safe, and more importantly, an effective device for characterization of propellant doughs/liquids. This is essential for developing a better understanding of processibility, ballistic, and mechanical behaviors of energetic materials. In this program, the development of a new rheometer system for energetic materials is discussed. The proposed device has several special features which are essential for the accurate measurement and characterization of solid filled composites. It has the capability of determining the critical conditions at which decomposition occurs, in addition to determining the conventional rheological parameters (i.e., for example, yield stress). The system has a special design for developing high shear rates as high as 100,000. s for special tests. During a constant flow rate test, without changing any device or sample of dough, a minimum of three different shear rate measurements can be taken simultaneously while controlling the shear history of the material. This feature makes it possible to obtain a complete rheological behavior (i.e., flow curve) of the materials up to three parameters, from a single test. Some viscoelastic properties (if any), including normal stress and relaxation time, can be predicted. Because of the special design and instrumentation of the test units, all measurements are taken without any assumption and/or corrections such as entrance effects and wall-slip phenomenon. All test units are temperature controlled independently. The system is simple and has well defined flow equations (stress/strain relationship). It is considered to be very safe, especially for clearing the leftover materials in the test devices. It is also self-functioning and portable, and can be used in both in-line and off-line rheology devices.
