An oxidizer that is soluble in a polar solvent selected from ethanol, diel ether, and acetone is used in a propellant composition mixing procedure to effect an improved dispersion of the oxidizer. The soluble oxidizer is selected from the reaction products formed by reacting together an equivalent amount of a first reactant selected from triethanol amine or diethanol amine with an equivalent amount of a second reactant perchloric acid when the soluble perchlorate salt is desired for use. The soluble oxidizer is selected from the reaction products formed by reacting together an equivalent amount of a first reactant selected from triethanol amine or diethanol amine with an equivalent amount of a second reactant nitric acid when the soluble nitrate salt is desired for use. The dissolved oxidizer is added to the binder portion of the propellant during mixing. After being widely dispersed, the soluble oxidizer and binder portion are mixed under low vacuum and mild heat (e.g., 110.degree. F. to 120.degree. F.) to remove the polar solvent thereby leaving the oxidizer in a widely dispersed state. The other propellant ingredients are added and mixing is continued to achieve homogenity prior to forming and curing the propellant for its intended use. The propellant composition with the widely dispersed oxidizer shows improved burning rate.

Solutions and process are described useful to produce coated HE powder granules in an aqueous slurry agglomeration process. A reaction mixture is made utilizing a lacquer stock solution comprising a binder material dissolved in a substantially aqueous-immiscible organic lacquer solvent, and an aqueous HE powder slurry solution comprising a non-aqueous soluble HE powder and an at least partially aqueous-miscible organic co-solvent. The co-solvent acts as an entrainer and improves the immiscible of the lacquer solvent in the water phase of the aqueous HE powder slurry solution, resulting in formation of HE powder agglomerates that remain stable as the solvents are removed from the reaction mixture during the agglomeration process. Further, the process is adjustable to substantially eliminate organic solvent contamination of the waste water stream.

A castable explosive composition of 80 to 87 percent cyclo-1,3,5,7-tetramylene-2,4,6,8-tetra nitramine (HMX) in dinitropropyl acrylate binder is obtained through careful choice of particle sizes. Up to 92% solids loading, without loss of castability, is obtained when spherical aluminum is incorporated into the mix. Other comonomers may be used in the binder and other solids added.

An improved multifunctional polyalkylene oxide binder is obtained by tailoring the cross-linking with a multifunctional polyol having a functionality of 3 or more and a molecular weight from about 12,000 to about 27,000 daltons. The binder is useful in forming castable propellants and plastic-bonded explosive compositions having high tensile strength and elongation and low volume dilatation.