Controllable assembly of BaCrO4@B core shell energetic microspheres based on micro-scale multiphase flow: Precise structural design and energy modulation

Precise structural modulation is critical for the functionalization of energetic materials. This study proposes a novel assembly strategy for BaCrO 4 @B core-shell microspheres based on micro-scale multiphase flow regulation. High-quality BaCrO 4 cores (sphericity >95%) were prepared via droplet ejection, followed by uniform coating of Boron/NC shells using pneumatic atomization. The surface morphology, elemental distributions, crystal structures, and pore architectures of the composite microspheres were systematically characterized, while their non-isothermal thermal decomposition behaviors and laser-ignited combustion characteristics were comprehensively evaluated. The study elucidates a self-limiting deposition mechanism and binder bridging effect, enabling precise shell thickness regulation (12.5 wt%–19.2 wt% B). This "core-shell decoupling and sequential refinement" strategy provides an ideal platform for elucidating structure-performance relationships and customizing functional energetic materials.