Direct Writing of a 90 wt% Particle Loading Nanothermite

Dual feed progressive cavity pump extrusion system for functionally graded direct ink write 3D printing

Material extrusion Additive Manufacturing (AM), is one of the most widely practiced methods of AM. Fused Filament Fabrication (FFF) is what most associate with AM, as it is relatively inexpensive, and highly accessible, involving feeding plastic filament into a hot-end that melts and extrudes from a nozzle as the toolhead moves along the toolpath. Direct Ink Write (DIW) 3D printing falls into this same category of AM, however is primarily practiced in laboratory settings to construct novel parts from flowable feedstock materials. DIW printers are relatively expensive and often depend on custom software to print a part, limiting user-specificity. There have been recent advancements in multi-material and functionally graded DIW, but the systems are highly custom and the methods used to achieve multi-material prints are openly available to the public. The following article outlines the construction and operation method of a DIW system that is capable of printing that can produce compositionally-graded components using a dual feed progressive cavity pump extruder equipped with a dynamic mixer. The extruder and its capabilities to vary material composition while printing are demonstrated using a Prusa i3 MK3S+ desktop fused filament fabrication printer as the gantry system. This provides users ease of operation, and the capability of further tailoring to specific needs.

In Situ Electrochemical Construction of CuN3@CuCl Hybrids for Controllable Energy Release and Self-Passivation Ability

Advanced energetic materials (EMs) play a crucial role in the advancement of microenergetic systems as actuation parts, igniters, propulsion units, and power. The sustainable electrosynthesis of EMs has gained momentum and achieved substantial improvements in the past decade. This study presents the facile synthesis of a new type of high-performance CuN3@CuCl hybrids via a co-electrodeposition methodology utilizing porous Cu as the sacrificial template. The composition, morphology, and energetic characteristics of the CuN3@CuCl hybrids can be easily tuned by adjusting the deposition times. The resulting hybrids demonstrate remarkable energy output (1120 J·g-1) and good laser-induced initiating ability. As compared with porous CuN3, the uniform doping of inert CuCl enhances the electrostatic safety of the hybridized material without compromising its overall energetic characteristics. Notably, the special oxidizing behavior of CuCl gradually lowers the susceptibility of the hybrid material to laser and electrostatic stimulation. This has significant implications for the passivation or self-destruction of highly sensitive EMs. Overall, this study pioneers a new path for the development of MEMS-compatible EMs, facilitating further microenergetic applications.

Additive Manufacturing and Combustion Characteristics of Polyethylene Oxide/Aluminum/Copper Oxide-Based Energetic Nanocomposites for Enhancing the Propulsion of Small Projectiles

The application of nanoscale energetic materials (nEMs) composed of metal and oxidizer nanoparticles (NPs) in thermal engineering systems is limited by their relatively high sensitivity and complex three-dimensional (3D) formability. Polymers can be added to nEMs to lower the sensitivity and improve the formability of 3D structures. In this study, the effect of the addition of polyethylene oxide (PEO; polymer) on the combustion characteristics of aluminum (Al; fuel)/copper oxide (CuO; oxidizer)-based nEMs is investigated. With an increase in the PEO content, the resulting PEO/nEM composites are desensitized to relatively high electrical spark discharges. However, the maximum explosion-induced pressure decreases significantly, and the combustion flame fails to propagate when the PEO content exceeds 15 wt.%. Therefore, the optimal PEO content in a nEM matrix must be accurately determined to achieve a compromise between sensitivity and reactivity. To demonstrate their potential application as composite solid propellants (CSPs), 3D-printed disks composed of PEO/nEM composites were assembled using additive manufacturing. They were cross-stacked with conventional potassium nitrate (KNO₃)/sucrose (C₁₂H₂₂O₁₁)-based disk-shaped CSPs in a combustion chamber of small rocket motors. Propulsion tests indicated that the specific impulse of KNSU/PEO/nEM (nEMs: 3.4 wt.%)-based CSPs was at a maximum value, which is approximately three times higher than that of KNSU CSPs without nEMs. This suggests that the addition of an optimized amount of polymer to nEMs is beneficial for various CSPs with compromised sensitivity and reactivity and excellent 3D formability, which can significantly enhance the propulsion of small projectiles.

Quo Vadis, Nanothermite? A Review of Recent Progress

One of the groups of pyrotechnic compositions is thermite compositions, so-called thermites, which consist of an oxidant, usually in the form of a metal oxide or salt, and a free metal, which is the fuel. A characteristic feature of termite combustion reactions, apart from their extremely high exothermicity, is that they proceed, for the most part, in liquid and solid phases. Nanothermites are compositions, which include at least one component whose particles size is on the order of nanometers. The properties of nanothermites, such as high linear burning velocities, high reaction heats, high sensitivity to stimuli, low ignition temperature, ability to create hybrid compositions with other high-energy materials allow for a wide range of applications. Among the applications of nanothermites, one should mention igniters, detonators, microdetonators, micromotors, detectors, elements of detonation chain or elements allowing self-destruction of systems (e.g., microchips). The aim of this work is to discuss the preparation methods, research methods, direction of the future development, eventual challenges or problems and to highlight the applications and emerging novel avenues of use of these compositions.

Combining printing and nanoparticle assembly: Methodology and application of nanoparticle patterning

Functional nanoparticles (NPs) with unique photoelectric, mechanical, magnetic, and chemical properties have attracted considerable attention. Aggregated NPs rather than individual NPs are generally required for sensing, electronics, and catalysis. However, the transformation of functional NP aggregates into scalable, controllable, and affordable functional devices remains challenging. Printing is a promising additive manufacturing technology for fabricating devices from NP building blocks because of its capabilities for rapid prototyping and versatile multifunctional manufacturing. This paper reviews recent advances in NP patterning based on the combination of self-assembly and printing technologies (including two-, three-, and four-dimensional printing), introduces the basic characteristics of these methods, and discusses various fields of NP patterning applications.

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Nanoparticles (NPs) printing assembly is a good solution for patterned devices

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NPs assembly can be combined with 2D, 3D, and 4D printing technologies

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A variety of ink-dispersed NPs are available for printing assembly

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NPs printing assembly technology is applied for nanosensing, energy storage, photodetector

Effect of fluoropolymer content on thermal and combustion performance of direct writing high-solid nanothermite composite

The addition of fluoropolymers can improve the reactivity of Al and enhance the combustion performance of thermites. The thermal and combustion properties of F2311/Al/CuO with different mass fractions of F2311 were systematically studied.

Fabrication of Energetic Composites with 91% Solid Content by 3D Direct Writing

Direct writing is a rapidly developing manufacturing technology that is convenient, adaptable and automated. It has been used in energetic composites to manufacture complex structures, improve product safety, and reduce waste. This work is aimed at probing the formability properties and combustion performances of aluminum/ammonium perchlorate with a high solid content for direct writing fabrication. Four kinds of samples with different solid content were successfully printed by adjusting printing parameters and inks formulas with excellent rheological behavior and combustion properties. A high solid content of 91% was manufactured and facile processed into complex structures. Micromorphology, rheology, density, burning rate, heat of combustion and combustion performance were evaluated to characterized four kinds of samples. As the solid content increases, the density, burning rate and heat of combustion are greatly enhanced. Based on 3D direct writing technology, complex energetic 3D structures with 91% solid content are shaped easier and more flexibly than in traditional manufacturing process, which provides a novel way for the manufacture of complicated structures of energetic components.

Carbon Fibers Enhance the Propagation of High Loading Nanothermites: In Situ Observation of Microscopic Combustion

A major challenge in formulating and manufacturing energetic materials lies in the balance between total energy density, energy release rate, and mechanical integrity. In this work, carbon fibers are embedded into ∼90 wt % loading Al/CuO nanothermite sticks through a simple extrusion direct writing technique. With only ∼2.5 wt % carbon fiber addition, the burn rate and heat flux were promoted >2×. In situ microscopic observation of combustion shows that the carbon fiber intercept ejected hot agglomerates near the burning surface and enhanced heat feedback to the unreacted material. This study outlines how these approaches may enhance the propagation and reduce the two-phase flow losses.

PyroMEMS as Future Technological Building Blocks for Advanced Microenergetic Systems

For the past two decades, many research groups have investigated new methods for reducing the size and cost of safe and arm-fire systems, while also improving their safety and reliability, through batch processing. Simultaneously, micro- and nanotechnology advancements regarding nanothermite materials have enabled the production of a key technological building block: pyrotechnical microsystems (pyroMEMS). This building block simply consists of microscale electric initiators with a thin thermite layer as the ignition charge. This microscale to millimeter-scale addressable pyroMEMS enables the integration of intelligence into centimeter-scale pyrotechnical systems. To illustrate this technological evolution, we hereby present the development of a smart infrared (IR) electronically controllable flare consisting of three distinct components: (1) a controllable pyrotechnical ejection block comprising three independently addressable small-scale propellers, all integrated into a one-piece molded and interconnected device, (2) a terminal function block comprising a structured IR pyrotechnical loaf coupled with a microinitiation stage integrating low-energy addressable pyroMEMS, and (3) a connected, autonomous, STANAG 4187 compliant, electronic sensor arming and firing block.

Recent trends in nanothermites: Fabrication, characteristics and applications

Energetic materials (EMs) are a group of distinctive materials that release an enormous amount of amassed chemical energy in a short time when incited by external mechanical or thermal factors. They comprise of propellants, explosives, and pyrotechnics. Unlike conventional micro-energetic materials, nano energetic materials (nEMs), due to their smaller particle size ranging from 1–100 nm, exhibit higher specific surface area (~10–50 m2 g−1), reduced ignition temperatures from 2350 K to approx.1000 K for particle size from 100 μm to 100 nm respectively, higher energy densities (up to 50 MJ kg−1), burning rates ~30.48 mm s−1 at 6.894 kPa with specific impulses up to 542 s (5320 m s−1), low impact sensitivity (<4–35 J). Such exceptional properties of nano energetic composites, i.e., thermites (a combination of metal-fuel/metal oxide particles), find applications, namely in, munitions, pyrotechnics, energetic micro-electromechanical system (MEMS) chips. This review provides valuable insight into the synthesis methods of nano energetic composite systems (e.g., Al/CuO, Al/KMnO4, Al/Fe2O3, Al/SnO2, Silicon-based systems), their characteristic properties, behavior under certain conditions and applications. Furthermore, the review converses about the advancements made in the last few decades by many researchers, along with the technological gaps that need to be addressed for futuristic applications.

Core-Shell Structured Nanoenergetic Materials: Preparation and Fundamental Properties

Energetic materials, including explosives, pyrotechnics, and propellants, are widely used in mining, demolition, automobile airbags, fireworks, ordnance, and space technology. Nanoenergetic materials (nEMs) have a high reaction rate and high energy density, which are both adjustable to a large extent. Structural control over nEMs to achieve improved performance and multifunctionality leads to a fascinating research area, namely, nanostructured energetic materials. Among them, core-shell structured nEMs have gained considerable attention due to their improved material properties and combined multiple functionalities. Various nEMs with core-shell structures have been developed through diverse synthesis routes, among which core-shell structured nEMs associated with explosives and metastable intermolecular composites (MICs) are extensively studied due to their good tunability and wide applications, as well as excellent energetic (e.g., enhanced heat release and combustion) and/or mechanical properties. Herein, the preparation methods and fundamental properties of the abovementioned kinds of core-shell structured nEMs are summarized and the reasons behind the satisfactory performance clarified, based on which suggestions regarding possible future research directions are proposed.

A Facile Preparation and Energetic Characteristics of the Core/Shell CoFe2O4/Al Nanowires Thermite Film

In this study, CoFe2O4 is selected for the first time to synthesize CoFe2O4/Al nanothermite films via an integration of nano-Al with CoFe2O4 nanowires (NWs), which can be prepared through a facile hydrothermal-annealing route. The resulting nanothermite film demonstrates a homogeneous structure and an intense contact between the Al and CoFe2O4 NWs at the nanoscale. In addition, both thermal analysis and laser ignition test reveal the superb energetic performances of the prepared CoFe2O4/Al NWs nanothermite film. Within different thicknesses of nano-Al for the CoFe2O4/Al NWs nanothermite films investigated here, the maximum heat output has reached as great as 2100 J·g-1 at the optimal thickness of 400 nm for deposited Al. Moreover, the fabrication strategy for CoFe2O4/Al NWs is also easy and suitable for diverse thermite systems based upon other composite metal oxides, such as MnCo2O4 and NiCo2O4. Importantly, this method has the featured advantages of simple operation and compatibility with microsystems, both of which may further facilitate potential applications for functional energetic chips.

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

Synergistically Chemical and Thermal Coupling between Graphene Oxide and Graphene Fluoride for Enhancing Aluminum Combustion

Metal combustion reaction is highly exothermic and is used in energetic applications, such as propulsion, pyrotechnics, powering micro- and nano-devices, and nanomaterials synthesis. Aluminum (Al) is attracting great interest in those applications because of its high energy density, earth abundance, and low toxicity. Nevertheless, Al combustion is hard to initiate and progresses slowly and incompletely. On the other hand, ultrathin carbon nanomaterials, such as graphene, graphene oxide (GO), and graphene fluoride (GF), can also undergo exothermic reactions. Herein, we demonstrate that the mixture of GO and GF significantly improves the performance of Al combustion as interactions between GO and GF provide heat and radicals to accelerate Al oxidation. Our experiments and reactive molecular dynamics simulation reveal that GO and GF have strong chemical and thermal couplings through radical reactions and heat released from their oxidation reactions. GO facilitates the dissociation of GF, and GF accelerates the disproportionation and oxidation of GO. When the mixture of GO and GF is added to micron-sized Al particles, their synergistic couplings generate reactive oxidative species, such as CF_x and CF_xO_y, and heat, which greatly accelerates Al combustion. This work demonstrates a new area of using synergistic couplings between ultrathin carbon nanomaterials to accelerate metal combustion and potentially oxidation reactions of other materials.

In-operando high-speed microscopy and thermometry of reaction propagation and sintering in a nanocomposite

An important proposed mechanism in nanothermites reactions - reactive sintering - plays a significant role on the combustion performance of nanothermites by rapidly melting and coalescing aggregated metal nanoparticles, which increases the initial size of the reacting composite powders before burning. Here, we demonstrate a high-speed microscopy/thermometry capability that enables ~ µs time and ~ µm spatial resolution as applied to highly exothermic reaction propagation to directly observe reactive sintering and the reaction front at high spatial and temporal resolution. Experiments on the Al+CuO nanocomposite system reveal a reaction front thickness of ~30 μm and temperatures in excess of 3000 K, resulting in a thermal gradient in excess of 10⁷ K m^-1. The local microscopic reactive sintering velocity is found to be an order of magnitude higher than macroscale flame velocity. In this observed mechanism, propagation is very similar to the general concept of laminar gas reaction theory in which reaction front velocity ~ (thermal diffusivity x reaction rate)^1/2.