So I've run myself into a curious situation and perhaps the more knowledgeable folk here can share some of their wisdom with me.
I have not really worked much with K perchlorate based applications in practice (although I've done quite a bit of work on producing perchlorates by electrosynthesis). Lately I have tried to devise a visco fuse formulation based on KClO4 (preferably a simple one) and to my amazement I have found the potassium salt to be so stable that it simply does not want to produce a decent fuse that burns reliably.
I've tried several combinations with carbon as the fuel (70/30, 80/20, 75/25 KCLO4/C), I've tried to add iron oxides as catalyst, I've tried adding a portion of Al powder and using erythritol as an experimental fuel.
The components were milled separately in electric grinder and then thoroughly mixed together. Ethyl alcohol was added and the damp powder granulated through a fine sieve several times. Then let dry until the granules flowed freely.
All of the combinations, although when burned as powder seem to work reasonably well, but produce a very feeble fuse that burns just barely and tends to go out on it's own. In contrast a 70/30 combination of KClO3/C turned into fuse by the very same process and visco machine produces profoundly excellent results. But for obvious reasons I would not like to use chlorates as the main component in a fuse formulation.
Are there any tested and true KClO4 based fuse formulations that anyone has had success with? Any tricks or tips for preparing the mix (apart from the obvious "get as well mixed as possible")?
I know that benzoates and terephtalates are supposed to work well in combination with K perchlorate as an agressive fuse formulation, but then again according to some expermentation reports that was supposed to be true also for carbon.
I was hoping to produce a more agressive fuse than the regular BP based formulations and also aimed to possibly use an excess of oxidiser to burn away the threads, but so far it seems quite hopeless. Even getting a consistent burn seems to be a real challenge.