Thermite Film Research Articles

Fabrication and Optimization Design of Multilayer Flyer Plates for Laser-Driven Loading

The laser-driven flyer plate is an important loading technology in high energy physics, shock wave physics, and explosive initiation application. How to generate a high-velocity and intact flyer plate by using the laser is a matter of concern for laser driving. In this study, the multilayer flyer plates (MFPs) of Al/Al2O3/Al and TiO2/Al/Al2O3/Al with adjustable performance were designed and fabricated by magnetron sputtering and analyzed by scanning electron microscopy (SEM), laser reflectance spectrometer, and differential thermal analysis (DTA). The effects of the structure and material on the output performance of MFPs were analyzed by photon Doppler velocimetry (PDV) and ultrahigh-speed video. The morphology results showed that the structure of MFPs had uniform and clear boundaries between side-by-side layers. The MFP velocity was controlled in the range of 4.0–6.0 km/s by adjusting the film thickness, structure, and thermite material with 43.1 J/cm2 laser ablation. Among them, the energetic flyers with the thermite ablation layer had the highest final velocity of 5.38 km/s due to the prestored energy of TiO2/Al. By appropriately increasing the thickness of Al2O3 from 0.4 μm to 0.8 μm, the complete flight of the flyer plate to 3.72 mm can be realized. In addition, TiO2/Al thermite film had characteristics of reaction heat release and lower laser reflectivity (72.13%) than the Al layer (80.55%), which explained the velocity enhancement effect of energetic flyer plates. This work provides facile strategy to enhance the output performance of MFPs, which may facilitate the practical applications of laser driving technology.

Electrophoretic deposition of hybrid organic-inorganic PTFE/Al/CuO energetic film

Thermite films are typical energetic materials (EMs) and have great value in initiating explosive devices. However, research in thermite film preparation is far behind that of research in thermite powders. Electrophoretic deposition (EPD) is an emerging, rapid coating method for film fabrication, including of energetic composite films. In this work, a polytetrafluoroethylene (PTFE)/Al/CuO organic-inorganic hybrid energetic film was successfully obtained using the above method for the first time. The addition of lithocholic acid as a surfactant into the electroplating suspension enabled PTFE to be charged. The combustion and energy release were analyzed by means of a high-speed camera and differential scanning calorimetery (DSC). It was found that the combustion process and energy release of PTFE/Al/CuO were much better than that of Al/CuO. The main reason for the excellent combustion performance of the hybrid PTFE/Al/CuO system was that the oxidability of PTFE accelerated the redox reaction between Al and CuO. The prepared PTFE/Al/CuO film was also employed as ignition material to fire a B–KNO3 explosive successfully, indicating considerable potential for use as an ignition material in micro-ignitors. This study sheds light on the preparation of fluoropolymer-containing organic-inorganic hybrid energetic films by one-step electrophoretic deposition.

Effect of the Ni and NiO Interface Layer on the Energy Performance of Core/Shell CuO/Al Systems.

The interface layer is responsible for the outward migration of oxygen atoms, which subsequently leads to an adjustment in the energetic performance of nanothermite films. In this study, sandwich-structured CuO@Ni/Al and CuO@NiO/Al nanowire thermite films were successfully prepared to investigate the effects of the interface layer on the heat-release, ignition, and combustion performance. The effects of the Ni and NiO interface layers are extremely different on the heat-release performance and combustion properties of the CuO/Al nanowire thermite film. Herein, the introduced Ni layer decreased the heat release (1979.7 J/g), reactivity (Ea = 177.3 kJ/mol), and maximum pressure (2.32 MPa) compared with the CuO/Al composite. Al/Ni alloys can be formed at the interface to prevent oxygen from diffusing between CuO and Al. Moreover, the incorporation of the Ni interface layer into the CuO/Al systems results in a heat drop due to its heat-absorption capability as well as its blockage of heat transfer from the thermite reaction. The deposition of the NiO layer between CuO and Al leads to an increase in the heat release (3014.2 J/g) and a decrease in the activation energy (Ea = 178.6 kJ/mol). The NiO layer endows the CuO/Al system with a high energy-release rate and chemical reactivity. NiO can participate in a thermite reaction, which promotes the reaction of CuO/Al and induces the condensed phase.

Electrochemical Synthesis of Al/CuO Thermite Films on Copper Substrates

The CuO micro/nanowires film has been prepared successfully on a Cu substrate using a combination of an electrochemical anodization and an annealing treatment. Its morphology and phase composition ...

Core/shell CuO/Al nanorod thermite film based on electrochemical anodization

In this study, a new method was reported for the fabrication of the nanostructured CuO/Al thermite film on a Cu substrate. The CuO nanorod (NR) arrays grew vertically from the Cu surfaces by electrochemical anodization processes, followed by the deposition of an Al layer on the CuO NRs via magnetron sputtering to form a core/shell CuO/Al nanothermite film, whose component, structure and morphology were subsequently characterized. In addition, the energy-release characteristics of the obtained nanothermite film were investigated using thermal analyses and laser ignition tests. All evidence demonstrates that the obtained CuO/Al is of a uniform structure and has superb energy performance. Impressively, the resulting material is potentially useful in applications of functional energetic chips due to its easy integration with microelectromechanical systems (MEMS) technologies.

Controllable synthesis of NiCo2O4/Al core-shell nanowires thermite film with excellent heat release and short ignition time

NiCo2O4 has been selected as an oxidizer to realize the nanothermite film for the first time in this study. The NiCo2O4/Al core-shell nanowires (NWs) thermite film has been fabricated using a facile hydrothermal-annealing synthesis method and a controllable magnetron sputtering process. The as-obtained NiCo2O4/Al NWs thermite film shows a uniform structure and distribution on the substrate, with a favorable interfacial contact between the bimetallic oxide and the fuel at the nanoscale. It is found that the quantity of Al plays a key role in the total heat release magnitude. The maximal heat release of the NiCo2O4/Al nanothermite film has reached 2076.0 J/g at the optimal Al deposited thickness of 450 nm with the obtained optimum Al/NiCo2O4 molar ratio of 4.9. Moreover, this design strategy is highly compatible with microelectromechanical systems (MEMs) and it can be applied to realize other nanothermites composed by bimetallic oxide and fuel.

The super-hydrophobic thermite film of the Co3O4/Al core/shell nanowires for an underwater ignition with a favorable aging-resistance

The energy performance of nanothermites in aqueous conditions is commonly restricted by the rapid heat dissipation and corrosion of nano-Al. Here we report studies on the fabrication and submerged ignition for the super-hydrophobic nanothermite film based upon the Co3O4/Al core/shell nanowires (NWs). The Co3O4 NWs arrays, which are synthesized using a facile hydrothermal-annealing method, serve as templates for the deposition of Al shells by magnetron sputtering. The super-hydrophobic surface is subsequently realized by the fluoroalkylsilane coating. The tests of the laser-induced underwater ignition reveal that the super-hydrophobic modification effectively could lead to the ignition of the nanothermite film. Furthermore, the anti-aging behaviors of the obtained super-hydrophobic nanothermite film in aqueous conditions are investigated in detail to compare the heat-release and ignition characteristics at different submersion times. Impressively, the resultant super-hydrophobic composite could still hold about 50% of the original energy even after an underwater storage of 2 days.

Investigation of Al/CuO multilayered thermite ignition

The ignition of the Al/CuO multilayered material is studied experimentally to explore the effects of the heating surface area, layering, and film thickness on the ignition characteristics and reaction performances. After the description of the micro-initiator devices and ignition conditions, we show that the heating surface area must be properly calibrated to optimize the nanothermite ignition performances. We demonstrated experimentally that a heating surface area of 0.25 mm2 is sufficient to ignite a multilayered thermite film of 1.6 mm wide by a few cm long, with a success rate of 100%. A new analytical and phenomenological ignition model based on atomic diffusion across layers and thermal exchange is also proposed. This model considers that CuO first decomposes into Cu2O, and then the oxygen diffuses across the Cu2O and Al2O3 layers before reaching the Al layer, where it reacts to form Al2O3. The theoretical results in terms of ignition response times confirm the experimental observation. The increase of the heating surface area leads to an increase of the ignition response time and ignition power threshold (go/no go condition). We also provide evidence that, for any heating surface area, the ignition time rapidly decreases when the electrical power density increases until an asymptotic value. This time point is referred to as the minimum response ignition time, which is a characteristic of the multilayered thermite itself. At the stoichiometric ratio (Al thickness is half of the CuO thickness), the minimum ignition response time can be easily tuned from 59 μs to 418 ms by tuning the heating surface area. The minimum ignition response time increases when the bilayer thickness increases. This work not only provides a set of micro-initiator design rules to obtain the best ignition conditions and reaction performances but also details a reliable and robust MicroElectroMechanical Systems process to fabricate igniters and brings new understanding of phenomena governing the ignition process of Al/CuO multilayers.

Fabrication and kinetics study of nano-Al/NiO thermite film by electrophoretic deposition.

Nano-Al/NiO thermites were successfully prepared as film by electrophoretic deposition (EPD). For the key issue of this EPD, a mixture solvent of ethanol-acetylacetone (1:1 in volume) containing 0.00025 M nitric acid was proved to be a suitable dispersion system for EPD. The kinetics of electrophoretic deposition for both nano-Al and nano-NiO were investigated; the linear relation between deposition weight and deposition time in short time and parabolic relation in prolonged time were observed in both EPDs. The critical transition time between linear deposition kinetics and parabolic deposition kinetics for nano-Al and nano-NiO were 20 and 10 min, respectively. The theoretical calculation of the kinetics of electrophoretic deposition revealed that the equivalence ratio of nano-Al/NiO thermites film would be affected by the behavior of electrophoretic deposition for nano-Al and nano-NiO. The equivalence ratio remained steady when the linear deposition kinetics dominated for both nano-Al and nano-NiO. The equivalence ratio would change with deposition time when deposition kinetics for nano-NiO changed into parabolic kinetics dominated after 10 min. Therefore, the rule was suggested to be suitable for other EPD of bicomposites. We also studied thermodynamic properties of electrophoretic nano-Al/NiO thermites film as well as combustion performance.

A pressure-driven flow analysis of gas trapping behavior in nanocomposite thermite films

This article is in direct response to a recently published article entitled Electrophoretic deposition and mechanistic studies of nano-Al/CuO thermites (K. T. Sullivan et al., J. Appl. Phys., 112(2), 2012), in which we introduced a non-dimensional parameter as the ratio of gas production to gas escape within a thin porous thermite film. In our original analysis, we had treated the problem as Fickian diffusion of gases through the porous network. However, we believe a more physical representation of the problem is to treat this as pressure-driven flow of gases in a porous medium. We offer a new derivation of the non-dimensional parameter which calculates gas velocity using the well-known Poiseuille's Law for pressure-driven flow in a pipe. This updated analysis incorporates the porosity, gas viscosity, and pressure gradient into the equation.

Micro-chip initiator realized by integrating Al/CuO multilayer nanothermite on polymeric membrane

We have developed a new nanothermite based polymeric electro-thermal initiator for non-contact ignition of a propellant. A reactive Al/CuO multilayer nanothermite resides on a 100 µm thick SU-8/PET (polyethyleneterephtalate) membrane to insulate the reactive layer from the silicon bulk substrate. When current is supplied to the initiator, the chemical reaction Al+CuO occurs and sparkles are spread to a distance of several millimeters. A micro-manufacturing process for fabricating the initiator is presented and the electrical behaviors of the ignition elements are also investigated. The characteristics of the initiator made on a 100 µm thick SU-8/PET membrane were compared to two bulk electro-thermal initiators: one on a silicon and one on a Pyrex substrate. The PET devices give 100% of Al/CuO ignition success for an electrical current >250 mA. Glass based reactive initiators give 100% of Al/CuO ignition success for an electrical current >500 mA. Reactive initiators directly on silicon cannot initiate even with a 4 A current. At low currents (<1 A), the initiation time is two orders of magnitude longer for Pyrex initiator compared to those obtained for PET initiator technology. We also observed that, the Al/CuO thermite film on PET membrane reacts within 1 ms (sparkles duration) whereas it reacts within 4 ms on Pyrex. The thermite reaction is 40 times greater in intensity using the PET substrate in comparison to Pyrex.

Significantly Enhanced Energy Output from 3D Ordered Macroporous Structured Fe2O3/Al Nanothermite Film

A three-dimensionally ordered macroporous Fe(2)O(3)/Al nanothermite membrane has been prepared with a polystyrene spheres template. The nanothermite, with an enhanced interfacial contact between fuel and oxidizer, outputs 2.83 kJ g(-1) of energy. This is significantly more than has been reported before. This approach, fully compatible with MEMS technology, provides an efficient way to produce micrometer thick three-dimensionally ordered nanostructured thermite films with overall spatial uniformity. These exciting achievements will greatly facilitate potential for the future development of applications of nanothermites.

Electrophoretic deposition and mechanistic studies of nano-Al/CuO thermites

Electrophoretic deposition was used to deposit thin films (∼10–200 μm) of nano-aluminum/copper oxide thermites, with a density of 29% the theoretical maximum. The reaction propagation velocity was examined using fine-patterned electrodes (0.25 × 20 mm), and the optimum velocity was found to correspond to a fuel-rich equivalence ratio of 1.7. This value did not correlate with the calculated maximum in gas production or temperature, and it is suggested that it is a result of enhanced condensed-phase transport, which is speculated to increase for fuel-rich conditions. A ∼25% drop in propagation velocity occurred above an equivalence ratio of 2.0, where Al2O3 is predicted to undergo a phase change from liquid to solid. This is expected to hinder the kinetics by decreasing the mobility of condensed-phase reacting species. The effect of film thickness on propagation velocity was investigated, using the optimum equivalence ratio. The velocity was seen to exhibit a two-plateau behavior, with one plateau between 13 and 50 μm film thickness, and the other above ∼120 μm. The latter had nearly an order of magnitude faster velocity than the former, 36 m/s vs. 4 m/s, respectively. For film thicknesses in the 50-120 μm range, a linear transitional regime was observed. Images from the combustion studies showed an increase in forward-transported particles as the film thickness increased, along with more turbulent behavior of the flame. It was suggested that the two-plateau behavior indicated a shift in the energy transport mechanism. While nanocomposite thermites have been traditionally thought to exhibit convective energy transport, we find in this work that particle advection may also be important. The velocity of particles ejected through a thin slit mounted above a thermite strip was measured, and was found to be even faster (∼2-3×) than the flame propagation velocity. The morphology of captured particles was examined with an electron microscope, and indicated that reactive sintering had occurred. A non-dimensional number (A) was used to relate the rate of gas pressurization (1/τp) to the rate of gas escape by Fickian diffusion (D/L2), A = L2/(D*τp). For small values of A, gases rapidly escape and do not accumulate within the thermite films. Thus, the resultant energy transport is relatively slow. For large values of A, gases are entirely trapped, thus activating enhanced energy transport via oscillating pressure buildup and unloading of the material. This analysis is suitable for thermites which can produce sufficient gas to raise the local pressure above some critical value to overcome material adhesion strength, inducing pressure-driven unloading and resulting in enhanced energy transport. We suggest that further improvements in nanocomposite thermites can be made by examining the coupling of multiple length scales. Not only is nano-scale mixing important, in this work we found that a second length scale (∼120 μm) was necessary to fully activate a pressure buildup/unloading mechanism, which significantly enhances the reactivity.