To better understand the thermal decomposition and reaction process of a fluorine-containing powdery thermite, PTFE/Al/MnO₂, reactions at different temperatures were investigated by the TG/DSC-MS technique. The corresponding reaction products were characterized with XRD phase analysis. Another three thermite materials, i.e., PTFE/Al, Al/MnO₂, and PTFE/MnO₂, were also prepared for comparison. Results showed that PTFE behaved as both oxidizer and reducer in PTFE/Al/MnO₂ fluorinated thermite. The thermal decomposition and reaction process of as-fabricated ternary thermite could be divided into two stages—the mutual reaction between each of PTFE, Al, and MnO₂ and the subsequent reaction produced between Al and Mn₂O₃/Mn₃O₄/MnF₂. Compared with the three control systems, the specially designed ternary system possessed a shorter reaction time, a faster energy release rate, and a better heat release performance.

Al-PTFE (aluminum-polytetrafluoroethene) is regarded as one of the most promising reactive materials (RMs). In this work, Ni (Nickel) was added to Al-PTFE composites for the purpose of improving the energy density and damage effect. To investigate the thermal behavior, mechanical properties and reaction characteristics of the Al-Ni-PTFE composites, an Al-PTFE mixture and an Al-Ni mixture were prepared by ultrasonic mixing. Six types of Al-Ni-PTFE specimens with different component mass ratios were prepared by molding sintering. Simultaneous thermal analysis experiments were carried out to characterize the thermal behavior of the Al-PTFE mixture and the Al-Ni mixture. Quasi-static compression tests were performed to analyze the mechanical properties and reaction characteristics of the Al-Ni-PTFE specimens. The results indicate that the reaction onset temperature of Al-Ni (582.7 °C) was similar to that of Al-PTFE (587.6 °C) and that the reaction heat of Al-Ni (991.9 J/g) was 12.5 times higher than that of Al-PTFE (79.6 J/g). With the increase of Ni content, the material changed from ductile to brittle and the strain hardening modulus and compressive strength rose first and then subsequently decreased, reaching a maximum of 51.35 MPa and 111.41 MPa respectively when the volume fraction of Ni was 10%. An exothermic reaction occurred for the specimens with a Ni volume fraction no more than 10% under quasi-static compression, accompanied by the formation of Ni-Al intermetallic compounds. In the Al-Ni-PTFE system, the reaction between Al and PTFE preceded the reaction between Al and Ni and the feasibility of increasing the energy density and damage effect of the Al-Ni-PTFE reactive material by means of Ni-Al reaction was proved.

Polytetrafluoroethylene/aluminum/molybdenum oxide (PTFE/Al/MoO₃) reactive composites of a volume ratio of 60:16:24 were studied in this research. Quasi-static compression, dynamic compression and drop-weight experiments were performed to explore the mechanical response and the shear-induced initiation properties of the composites. Mesoscale images of the specimens after sintering demonstrate that PTFE, Al and MoO₃ powders were evenly mixed and no chemical reaction occurred after the materials were stirred, pressed and sintered. The yield stress and compressive strength of PTFE/Al/MoO₃ specimens are sensitive to strain rate within the range of 10⁻³~3 × 10³ s⁻¹, and the yield stress shows a bilinear dependence on the logarithm values of strain rate. The established Johnson-Cook constitutive model based on the experimental data can describe the mechanical response of PTFE/Al/MoO₃ material well. Drop-weight tests show that the PTFE/Al/MoO₃ specimens can react violently when impacted, with the characteristic drop height (H₅₀) calculated as 51.57 cm. The recovered specimens show that the reaction started from the outer edge of the specimen with the largest shear force and the most concentrated shear deformation, indicating a shear-induced initiation mechanism. The reaction products of PTFE/Al/MoO₃ specimens were AlF₃, Al₂O₃, Mo and C, demonstrating that redox reaction occurred between PTFE and Al, and between Al and MoO₃.

Al‐PTFE (aluminum‐polytetrafluoroethylene) serves as one among the most promising reactive materials (RMs). In this work, six types of Al‐PTFE composites with different Al particle sizes (i.e., 50 nm, 1∼2 μm, 6∼7 μm, 12∼14 μm, 22∼24 μm, and 32∼34 μm) were prepared, and quasistatic compression and drop weight tests were conducted to characterize the mechanical properties and reaction characteristics of Al‐PTFE composites. The reaction phenomenon and stress‐strain curves were recorded by a high‐speed camera and universal testing machine. The microstructure of selected specimens was anatomized through adopting a scanning electron microscope (SEM) to correlate the mesoscale structural characteristics to their macroproperties. As the results indicated, in the case of quasistatic compression, the strength of the composites was decreased (the yield strength falling from 22.7 MPa to 13.6 MPa and the hardening modulus declining from 33.3 MPa to 25 MPa) with the increase of the Al particle size. The toughness rose firstly and subsequently decreased and peaked as 116.42 MJ/m³ at 6∼7 μm. The reaction phenomenon occurred only in composites with the Al particle size less than 10 μm. In drop weight tests, six types of specimens were overall reacted. As the Al particle size rose, the ignition energy of the composites enhanced and the composites turned out to be more insensitive to reaction. In a lower strain rate range (10⁻²·s⁻¹∼10²·s⁻¹), Al‐PTFE specimens take on different mechanical properties and reaction characteristics in the case of different strain rates. The formation of circumferential open cracks is deemed as a prerequisite for Al‐PTFE specimens to go through a reaction.

When the Al/Ta/PTFE reactive material was sintered at 360 °C in a vacuum sintering furnace, it was found that the material reacted to form a soft fluffy white substance and carbon black. To explore the reaction process further, powder samples of pure PTFE, Al/PTFE, Ta/PTFE and Al/Ta/PTFE, and molded cylindrical specimens were prepared. A TG-DSC test was carried out on the thermal reaction of four reactive materials, and XRD phase analysis was conducted on the white product, formed by the sintering reaction and the residue of the TG-DSC test sample, based on which of the pyrolysis processes and reaction mechanisms were analyzed. The results show that Ta and PTFE could have a chemical reaction at sintering temperature (360 °C) to form soft and fluffy white material TaF₃ and carbon black, which can overflow the surface of the specimen and cause cracking of the specimen, which is tightly pressed. Since no obvious exothermic peak showed up on the TG-DSC curve, the composition of the residue of TG-DSC sample at different temperatures was tested and TaF₃ was detected in the residue at 350 °C and 360 °C, indicating that Ta began to react with PTFE at a temperature range of 340–350 °C. According to the chemical properties and product formation of Ta, it could be speculated that the reaction mechanism between Ta and PTFE involves the PTFE decomposing first, then the fluorine-containing gas product reacting with metal Ta. According to the temperature range of the reaction, it is estimated that PTFE starts to decompose before 500 °C, but it is not detected effectively by TG-DSC, and the introduction of Ta could also affect the decomposition process of PTFE.