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Reactive Ni−Al materials have been developed using a variety of methods, with high energy ball milling (HEBM) being one of the most common means for tailoring reaction behavior. Powder production limitations associated with HEBM, including the addition of process control agents, have inspired the exploration of an alternate manufacturing technique: acoustic dry milling with the Resodyn Laboratory Resonant Acoustic Mixer (LabRAM). The influence of acoustic milling time, intensity, and media size with respect to microstructure and reactive behavior of Ni−Al powders were evaluated in this work. After just 20 min of milling, a reactive composite Ni−Al microstructure was produced. Milling intensity and media size were directly proportional to the formation of more homogeneous composite powders. The reaction onset temperature was decreased to 446 °C, or ≈200 °C lower than that of unprocessed material. The method shows promise for the production of reactive powder for a host of applications. [ABSTRACT FROM AUTHOR]

The combustion of mixed homogeneous pyrotechnic compositions and heterogeneous charges is studied experimentally with the aim of producing a selectable wavelength signal flare. The heterogeneous charge was perceived as a mixed color by a distant observer. A model for color chromaticity coordinates of homogeneous mixtures was derived that includes the mass, mass‐based burn rate and luminous intensity ratios of the constituting color compositions. This model can predict the expected dominant wavelength of a mixed composition. It can also handle the spacing of chromaticity coordinates of mixed compositions on a straight line in the CIE diagram between chromaticity coordinates of constituting colors. With two series of color composition mixtures, it was demonstrated that the chromaticity coordinates of the mixtures could be at, or slightly deviate, from the straight line connecting the chromaticity coordinates of the constituting compositions. It indicates there is little to no influence of flame temperature and mutual pyrotechnic reactions. [ABSTRACT FROM AUTHOR]

The ever‐present threat of biological weapons has encouraged the development of novel pyrotechnic formulations that release gaseous iodine upon combustion, which acts as a potent active agent capable of countering bio‐agents (e. g. anthrax). These formulations typically contain a fuel (Al, B, Al/B4C) and an iodate serving as an oxidizer. However, the percentage of free iodine generated is relatively low and aging of these formulations remains an issue. In this work, the role of particle size on the combustion velocities, iodine output, and combustion products are detailed for a boron carbide/sodium periodate formulation. Formulations are studied with and without the addition of binder (protectant) and the role of particle size on achieving 3‐D printable energetics is detailed. It is found that altering the fuel particle size (boron carbide) had little effect on the combustion velocity and iodine recovery. However, by reducing the particle size of the oxidizer, NaIO4, drastic improvements in iodine recovery are achieved. A reduction in mean particle size from 215 to 3 μm resulted in a 47 % increase in observed iodine recovery for powder formulations. Combustion velocities appear to be unaffected and were 1.4–1.6 mm/s. An in‐depth discussion of the decomposition pathway of pure NaIO4 as well as when paired with a B4C fuel source is also discussed. [ABSTRACT FROM AUTHOR]

Double base propellants composed of nitrocellulose (NC) and nitroglycerine (NG) are widely used. However, the inclusion of liquid NG presents both stability and performance problems: the NG may migrate from the propellant in storage, and it softens the propellant at high inclusion levels. In this work, the novel nitrate ester 1,4-dinitrato-2,3-dinitro-2,3bis(nitratomethylene) butane (SMX) is considered as a replacement for NG in a double base propellant. Thermochemical calculations indicate improved performance when compared with the common double base propellant JA2 at SMX loadings above 40 wt-%. Also, since SMX is a room temperature solid, migration may be mitigated. Both unplasticized and plasticized propellants were formulated to enable the study of the interaction of SMX with nitrocellulose. Thermal analysis of unplasticized propellant showed a distinct melt-recrystallization curve, which indicates that a solid phase solution is being formed between SMX and NC, and that SMX would not act as plasticizer. Analysis of propellant prepared with diethyleneglycol dinitrate (DEGDN) plasticizer indicates that the SMX is likely dissolved in the DEGDN. The plasticized material also showed similar hardness and modulus to JA2. Safety characterization showed that sensitivity is similar to JA2. In short, replacing NG with SMX results in a new family of propellants with acceptable safety characteristics and which may also offer improved theoretical performance. [ABSTRACT FROM AUTHOR]

Replacement reactive systems for the tungsten delay composition (W/BaCrO4/KClO4/diatomaceous earth) are needed due to recent concerns over the toxicity of hexavalent chromium and perchlorates. Systems based on condensed phase reactions, that are typically used in combustion synthesis (e.g., Ti/C or Ni/Al) are of interest as replacements due to their wide range of combustion velocities and potentially low environmental impact. In this work, the combustion characteristics of the Ti/C-3Ni/Al reactive system were examined in microchannels with inner diameters ranging from 3.0-6.0 mm (i.e., similar to that of a common delay housing). It was found that this reactive system could be tailored to overcome the heat losses associated with small diameter microchannels by changing the relative amounts of Ti/C and 3Ni/Al. At 40 wt.-% Ti/C content, the failure diameter was found to be between 3.0 and 4.0 mm, while at 30 wt.-% Ti/C the failure diameter was between 4.8 and 6.0 mm. Measured combustion temperatures in metal microchannels were approximately 1700 K while those of unconfined pellets were around 100 K greater. Increasing Ti/C content resulted in faster combustion velocities while decreasing microchannel diameter resulted in slower combustion velocities. At these small sizes the effects of adding a thermal barrier (specifically Grafoil™) to minimize radial heat losses to the microchannel were shown to be minimal with respect to combustion velocity. The Ti/C-3Ni/Al system was shown to be a suitable delay fuze composition with tunable combustion velocities ranging from 2.1-38.1 mm s−1 in aluminum microchannels with diameters ranging from 4.0-6.0 mm. [ABSTRACT FROM AUTHOR]

Sensitive nanoenergetic powders, such as nanothermites, have traditionally been processed by ultrasonic mixing of very low solids loaded suspensions in organic solvents, which has restricted their use and application due to high solvent content and associated handling issues. In this work, we report on the performance and mixing quality of nanothermite mixtures prepared in a LabRAM resonant mixer at high solids loadings as compared to ultrasonic mixing. Specifically, the aluminum-bismuth(III) oxide (Al/Bi2O3) system processed in the polar solvent N, N-dimethylformamide (DMF) was investigated. It was found that the performance and overall quality of mixing was strongly correlated to the volumetric solids loading during processing; increasing volumetric solids loading decreases separation of particles, leading to more particle interaction and more intimate mixing. The measured performance of this system processed at 30 vol-% was similar to traditionally ultrasonicated mixtures. Increasing the solids loading above 30 vol-% yielded diminishing returns in performance and may introduce additional safety concerns since dry powders are very sensitive to electrostatic discharge. This mixing approach uses significantly less solvent than traditional ultrasonic mixing, results in a higher density final material, and is amenable to scaling. In addition, solvent wetted nanothermite mixed at 30 vol-% solids loading can be mixed and deposited from a single applicator and was observed to be over five orders of magnitude less sensitive to electrostatic discharge than dry powders. This relative insensitivity enables the safe deposition of high density nanothermite ink onto devices. [ABSTRACT FROM AUTHOR]

Micrometer-sized aluminum is widely used in energetics; however, performance of propellants, explosives, and pyrotechnics could be significantly improved if its ignition barriers could be disrupted. We report morphological, thermal, and chemical characterization of fuel rich aluminum-polytetrafluoroethylene (70-30 wt-%) reactive particles formed by high and low energy milling. Average particle sizes range from 15-78 μm; however, specific surface areas range from approx. 2-7 m2 g−1 due to milling induced voids and cleaved surfaces. Scanning electron microscopy and energy dispersive spectroscopy reveal uniform distribution of PTFE, providing nanoscale mixing within particles. The combustion enthalpy was found to be 20.2 kJ g−1, though a slight decrease (0.8 kJ g−1) results from extended high energy milling due to α-AlF3 formation. For high energy mechanically activated particles, differential scanning calorimetry in argon shows a strong, exothermic pre-ignition reaction that onsets near 440 °C and a second, more dominant exotherm that onsets around 510 °C. Scans in O2-Ar indicate that, unlike physical mixtures, more complete reaction occurs at higher heating rates and the reaction onset is drastically reduced (approx. 440 °C). Simple flame tests reveal that these altered Al-polytetrafluoroethylene particles light readily unlike micrometer-sized aluminum. Safety testing also shows these particles have high electrostatic discharge (89.9-108 mJ), impact (>213 cm), and friction (>360 N) ignition thresholds. These particles may be useful for reactive liners, thermobaric explosives, and pyrolants. In particular, the altered reactivity, large particle size and relatively low specific surface area of these fuel rich particles make them an interesting replacement for aluminum in solid propellants. [ABSTRACT FROM AUTHOR]