Fully-Dense High Performance Nanocomposite Thermite Powders Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-020 Topic Title: Fully-Dense High Performance Nanocomposite Thermite Powders Proposal No.: N081-020-0728 Firm: Reactive Metals Incorporated 294 Hana Rd Edison, New Jersey 08817-2048 Contact: Phone: (732) 261-4876 Abstract: This program will develop a low-cost technique for manufacturing nanocomposite thermite powders with performance matching or exceeding that of the currently available superthermites prepared using ultrasonication of nano metal and nano metal oxide powders. The technique to be developed will eliminate the need in starting nanopowders, which are relatively expensive, difficult to handle, and present an inherent problem of reduced active metal content. The technique to be developed in the project will utilize mechanical milling of commercially available micron-sized powders of aluminum and metal oxides and will further develop a recently proposed approach of Arrested Reactive Milling (ARM). ARM has been shown to offer a scalable process yielding an energetic powder that can be very inexpensive. However, ARM-produced powders have never been directly compared to conventional nano-energetic compositions prepared by ultrasonic mixing of starting nanopowders. In this Phase I program, comparisons of ARM produced and ultrasonicated powders with the same compositions will be made. Constant volume explosions will be used as one of the comparison tools. Sensitivities and other characteristics of different superthermite systems will also be assessed experimentally. Benefits: Proposed technique will enable economic and scalable manufacturing of advanced reactive nanocomposite materials. Such materials will replace energetic formulations in pyrotechnic, explosive, and propellant compositions. The main benefit will be increased energy density without the sacrifice in the reaction rate, typical for currently used metal-based energetic formulations. The materials to be manufactured using the proposed technique will combine the benefits of superthermites prepared by ultrasonication with low cost and higher energy density. In addition, all handling, safety, and health concerns associated with using nanopowders will be alleviated because no nanopowders will be used in the new materials. Additional applications include mining explosives, commercial pyrotechnics (e.g., airbag gas generators and igniters), and advanced thermite welding. Return