A Novel Processing Technique for the Large-Scale Production of High Energy Density Solid Fuel Air Explosives

Current techniques for the production of spherical, micron size, monodisperse metal powders such as comminution, atornization and gas phase synthesis cannot produce reactive metal powders on a large-scale while maintaining a pure surface. Coating of these highly reactive metal powders with a passivating layer requires special handling. Conventional processing techniques such as fluidized bed and electrostatic spray are unable to provide an inert atmosphere, but more importantly, cannot be scaled up to large-scale production. A novel new technique recently developed at MER has demonstrated the potential for producing large-scale quantities of spherical, micron size, pure metals, intermetallics and alloy powders. In addition, a thin passivating layer of fullerenes will be deposited on these powders by liquid phase precipitation to prevent premature reaction. The unique properties of fullerenes, the third allotrope of carbon, will be utilized to produce reactive metal powders that will participate in the combustion reactions at much lower temperatures possible to date. This Phase I program will demonstrate that this novel process, combined with a fullerene coating process, is the preferred technique for the economical large-scale production of high performance solid fuel air explosives.