Economical method for fabricating high-quality super-thermites Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-020 Topic Title: Economical method for fabricating high-quality super-thermites Proposal No.: N081-020-1024 Firm: Physical Sciences Inc. 20 New England Business Center Andover, Massachusetts 01810-1077 Contact: Edward Salley Phone: (978) 689-0003 Web Site: http://www.psicorp.com Abstract: Current techniques used to fabricate super-thermites are not cost-effective. To address this issue Physical Sciences Inc. (PSI) intends to develop a cryomilling process that is capable of achieving low-cost production of these materials through the use of micron-sized starting materials. The cryomilling process is readily scaleable, reproducible, safe, and flexible. The inherent nature of the process will eliminate and/or reduce risk of spontaneous ignition, partial oxidation of components, and contamination by milling media. Other expected benefits of the cryomilling process to be developed include producing super-thermite powders with increased exothermicity and lower ignition temperature over those currently fabricated using ultrasonically mixed nanopowders. During the Phase 1 effort PSI will produce aluminum/copper oxide super-thermite powder, characterize the powder and process, and provide a cost analysis of its manufacturing. The Phase 1 option will extend the method to produce additional super-thermite compositions including aluminum/molybdenum oxide and aluminum/bismuth oxide. The Phase II effort will demonstrate scaleability and reproducibility of the process to the kilogram/day level and further investigate the combustion characteristics of the nanocomposite powder. Benefits: A process for fabricating low cost super-thermites will enable both more efficient use of research dollars in exploring this field and will demonstrate a path to commercialization of these nano-dimensional materials. These powders are expected to provide enhanced properties over standard thermites including higher energy content and faster reaction rates per unit volume. Once realized, the material can used to provide a lower cost replacement to existing energetic materials or provide more lethality for a given volume. Return