Modeling of Sustainable B/B4C/Bi2O3 Pyrotechnic Compositions Using RSM

Pyrotechnic compositions are energetic materials with highly application-specific formulations, whose combustion behavior remains difficult to mathematically model due to complex multivariate interactions. Consequently, empirical approaches continue to be the most effective tools for formulation optimization. This work contributes to the field by establishing a statistically robust experimental framework that combines empirical testing with Response Surface Methodology (RSM) to model performance and sensitivity in ternary pyrotechnic mixtures while optimizing the number of required experiments. The study provided novel data on burning rate and electrostatic discharge (ESD) sensitivity—key performance and safety metrics—in formulations containing boron, boron carbide, and bismuth oxide, which remain largely unexplored. These materials were selected not only for their energetic potential but also for their reduced environmental impact. Burning rates ranging from approximately 6 to 20 mm/s and ESD minimum ignition energies between 2 and 11 mJ were measured across the investigated composition space and successfully described using response surface models, achieving a coefficient of determination of R² ≈ 0.99 for burning rate. The results demonstrate that RSM effectively captures nonlinear composition–property relationships in boron-based pyrotechnic systems, providing a practical framework for designing formulations that balance performance, electrostatic safety, and reduced environmental impact.