Tuning the morphological, ignition and combustion properties of micron-Al/CuO thermites through different synthesis approaches

Aluminum (Al)-based thermite, due to its high energy density and low cost, has found wide applications in aerospace propulsion, explosion, pyrotechnics, thermal batteries, and power generations. Though significant efforts have been devoted to improving the ignition and combustion performance of Al-based thermites by using nano-Al, micron-Al (m-Al) remains of practical importance over nano-Al due to its lower cost and smaller dead mass. For m-Al based thermite, the main approach to improve its ignition and combustion performance is to bring Al and metal oxide as close as possible to facilitate the oxidizer diffusion process. Herein, we demonstrated two simple synthesis methods, i.e., the precipitation (PC) method and displacement (DP) method, to prepare m-Al/CuO thermites with the intention to bring Al and CuO to shorter diffusion distance and achieve better dispersion. The PC-thermites have flocculent nanostructured CuO closely attached to the surface of m-Al, and the DP-thermites have a dense shell of CuO coated on the surface of m-Al. Both PC- and DP-thermites have reduced agglomeration and diffusion distance over the traditional mechanically mixed (MM)-thermites that have randomly distributed and agglomerated CuO and m-Al. Consequently, both PC- and DP-thermites exhibit shorter ignition delay time, lower reaction onset temperatures, higher heat release, larger pressure rise, and extended reactivity limits than MM-thermites. Particularly, PC-thermites, due to their flocculent structures, exhibit the shortest ignition delay time, lowest reaction onset temperature, and highest amount of heat release. Moreover, the superior ignition and combustion performance of PC- and DP-thermites is more pronounced under high heating rates over low heating rates. Similar PC and DP methods are applicable to prepare diverse thermites with reduced diffusion distance and improved dispersion to improve their ignition and combustion properties.