The production and study of highly dispersed aluminum-based powders represents one of contemporary science’s priority fields. This is primarily driven by the practical necessity to develop new materials, a feat that, in some cases, can only be achieved through the utilization of powdered components. This article presents the results of the mechanochemical treatment method employed to obtain highly reactive aluminum particles. It also includes a comparative analysis of aluminum particles generated through various methods and their respective properties. Furthermore, the application of these highly reactive aluminum particles in energy-intensive materials is discussed.

In this paper, the results of the technological combustion of SHS heat insulators based on mineral origins are presented. It is shown that after mechanochemical treatment of minerals—diatomite—the kinetic characteristics of the combustion process change, providing targeted formation of the phase composition, structure, and properties of the SHS composite. A positive effect of using various modifiers during the MCT of diatomite—the activation of the combustion process—was established. The selection of modifiers provides an increase in the strength of the synthesized SHS composites as a result of the formation of aluminate compounds in the synthesis products, and a decrease in thermal conductivity to 0.157 W/m*K due to the formation of the ultraporous structure of the samples.

Aluminium plays a key role in developing modern energy technologies, from electrical systems to high-energy materials, providing a combination of functionality, economy, and reliability, but the oxide film on its particles reduces the effective reactivity. This work aims to increase the reactivity of aluminum powder by mechanochemical treatment using modifiers. The materials used were aluminum powder of the ASD brand and graphite of the GL-1 brand. The experiment subjected aluminum powder to mechanochemical treatment (MCT) with different graphite contents. It was shown that MCT significantly increases active aluminum content in the powder due to partial destruction of the oxide film on its surface. In addition, morphological analyses confirm the destruction of the oxide, the graphite coating, and the appearance of lamellar structures measuring 0–58 µm. Thermal analysis shows that the primary exothermic peak shifts from 662.6 °C to 653.9 °C for Al + 10% graphite, and the heat released increases by 27%, which means lower activation energy and more complete oxidation. However, at 20% graphite, the thermal gain decreases, since carbon shields the metal areas. Thus, the optimal content is 10% graphite: at this ratio, the best thermochemical behavior of the powder is achieved. The data obtained indicate that the MCT of aluminum powder with graphite effectively increases its reactivity. The resulting aluminum powders with modified particle surfaces facilitate the development of new technologies for the creation of various high-energy solid propellant systems. For rocket engines, preference is given to solid rocket propellant (SRP), which is a mixture of substances (components) capable of burning in the absence of air, producing a large amount of gaseous working fluid heated to a high temperature, providing thrust.

This paper presents the results of a study of the effect of modifiers such as stearic acid, graphite and polyvinyl alcohol on the combustion characteristics of aluminum powder for gas generator compositions for oiland gas wells. The methodology used includes mechanochemical treatment of aluminum with various modifiers and subsequent analysis of their effect on the combustion rate and temperature of gas generators. The results demonstrate that the addition of stearic acid showed an increase in the combustion rate by 25%. These changes are confirmed by the results of infrared spectroscopy and thermogravimetric analysis, which emphasizes a significant improvement in combustion characteristics. The results of the study show that modification of aluminum powder allows for the creation of more efficient and safe fuel and explosive mixtures for gas generators with high specific energy capacity, reducing the risks associated with high ignition temperatures and incomplete combustion.

This work is devoted to the study of the influence of mechanical activation of aluminum, as well as its modification with graphite on the combustion processes of solid rocket propellant (SRP). Experiments were conducted to determine the ignition induction period, combustion rate and combustion products. Experimental work on ignition and combustion diagnostics was carried out using a diagnostic system at the Institute of Space Propulsion (ISP) of Nanjing University of Science and Technology. A multifunctional combustion diagnostic system was used to characterize the combustion processes of finished SRP samples. A high-speed camera was used to capture the combustion surface regression for various fuels, which can be used to derive their burning rate. The addition of graphite during the mechanochemical activation (MCA) of aluminum significantly affected particle shape and the state of the oxide film, improving the batch homogeneity and increasing the specific surface area. The optimal graphite concentration was approximately 10%, providing additional activation, while 20% graphite caused recoating of the particles and reduced processing efficiency. At constant pressure, it was found that MCA and the introduction of graphite accelerated composite combustion without disrupting stable combustion, with a relatively uniform front. The highest combustion velocity (3.0 mm s⁻¹) was achieved with 10% graphite due to effective heat transfer and catalysis, while increasing its content to 20% reduced the combustion velocity, indicating an optimum of approximately 10%.