Abstract: A process for preparing a porous propellant grain which comprises blending at least two combustible materials to form a homogeneous mixture, adding a predetermined amount of a liquid dispersant to said mixture to form a slurry, and flash drying the slurry in order to form a porous, single grain propellant having a greatly increased burning surface. A single grain propellant is produced having a flat, torroidal shape with a central cylindrical core and honeycombed with a plurality of porous channels extending entirely through the grain to increase the burning surface thereof.

Abstract: A gas generating composition is disclosed wherein the combustible reactants are an alkali metal azide and a metal oxide which upon thermal initiation react to produce alkali metal oxide, metal and pure nitrogen gas which can be used to inflate an impact protection air cushion of an automotive restraint system.