Advancements in the synthesis, catalytic activity, anti-migration properties and thermal stability of ferrocene-based burning rate catalysts for solid propellants

Composite solid propellants (CSPs) are essential for rocket propulsion, consisting of ammonium perchlorate (AP) as the oxidizer, a polymeric binder like hydroxyl‑terminated polybutadiene (HTPB) and functional additives, including burning rate catalysts. Ferrocene (Fc)-based burning rate catalysts are particularly effective in enhancing CSP performance by lowering thermal decomposition temperature of AP. However, issues such as the volatility and migration of Fc-based burning rate catalyst can limit their efficiency in CSPs. Recent advancements have focused on developing Fc-based polymers, nitrogen-rich derivatives and dendrimers to improve anti-migration, catalytic efficiency and thermal stability. In addition, synthesis of Fc-based bimetallic composites and their functionalization with carbon nanotubes, graphene oxide and zeolitic imidazolate frameworks (ZIFs) have shown potential in stabilizing Fc-based burning rate catalyst and enhancing their anti-migration and catalytic properties. Molecular dynamics simulations suggest that modifications like alkylation, polar functionalization, and cyclic structures improve stability, mechanical properties, and performance of Fc derivatives. This review consolidates latest advancements in Fc-based burning rate catalysts, offering insights into their role in optimizing CSP performance for advanced propulsion systems.