Economical method for fabricating high-quality super-thermites

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.