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Title: Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO₃) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO₄) additive on the combustion behavior of these energetic films. Without KClO₄ the film exhibits thermal instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO₄ increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO₄. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO₄ concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO₄ promotes stablemore » energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO₄ adding energy to the reaction and promoting propagation.« less
 [1] ;  [1] ;  [1] ;  [2] ;  [2]
  1. Texas Tech Univ., Lubbock, TX (United States). Mechanical Engineering Dept.
  2. Idaho National Lab. (INL), Idaho Falls, ID (United States)
Publication Date:
Grant/Contract Number:
Accepted Manuscript
Journal Name:
AIP Advances
Additional Journal Information:
Journal Volume: 5; Journal Issue: 8; Journal ID: ISSN 2158-3226
American Institute of Physics (AIP)
Research Org:
Idaho National Lab. (INL), Idaho Falls, ID (United States)
Sponsoring Org:
Country of Publication:
United States
36 MATERIALS SCIENCE; 37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY; flames; aluminum; combustion; solvents; composite materials
OSTI Identifier: