Pre-stressing aluminum (Al) particles by annealing and quenching alters dilatational strain and is linked to increased particle reactivity. The quenching rate associated with pre-stressing is a key parameter affecting the final stress state within the Al particle, with faster quenching rates theoretically favoring a higher, more desirable stress state. Micron scale Al particles are annealed to 573 K, then quenched at different rates (i.e., 200 and 900 K/min), mixed with bismuth oxide (Bi2O3), and the Al + Bi2O3 mixtures are examined under low-velocity, drop-weight impact conditions. Both quenching rates showed increased impact ignition sensitivity (i.e., between 83% and 89% decrease in ignition energy). However, the slower quenching rate showed a 100% increase in pressurization rate compared to untreated particles, while the faster quenching rate showed a 97% increase in peak pressure, indicating that these two quenching rates affect Al particles differently. Surprisingly, synchrotron X-ray diffraction data show that the 200 K/min quenched particles have a higher dilatational strain than the untreated particles or the 900 K/min quenched particles. Results are rationalized with the help of a simple mechanical model that takes into account elastic stresses, creep in the alumina shell, and delamination of shell from the core. The model predicts that Al powder quenched at 200 K/min did not experience delamination. In contrast, Al quenched at 900 K/min did not have creep but does have delamination, and under impact, delamination led to major fracture, greater oxygen access to the core, and significant promotion of reaction. Thus, the increase in quenching rate and shell-core delamination are more important for the increase in Al reactivity than pre-stressing alone.

Micron-scale aluminum (Al) particles are plagued by incomplete combustion that inhibits their reactivity. One approach to improving reactivity is to anneal Al particles to increase dilatational (volumetric) strain which has also been linked to increased combustion performance. While optimal annealing temperatures have been identified (roughly 300 °C), little is known about cooling rate effects on particle combustion performance. This study examines the effect of quenching after annealing Al microparticles to 100, 200 and 300 °C on intra-particle dilatational strain and reactivity. Synchrotron X-ray diffraction analysis of the particles reveals the cooling rates in the range from 0.007 to 0.38 K/s have little effect on the dilatational strain of the aluminum-core, alumina-shell particles. The annealed and quenched Al particles were then combined with a metal oxidizer (copper oxide) to examine reactivity. Flame propagation experiments follow the same trend: flame speeds are unchanged until a critical annealing temperature of 300 °C is reached and performance is maintained for each annealing temperature regardless of cooling rate. These results show that altering the mechanical properties and combustion performance of Al particles is strongly dependent on the annealing temperature and unchanged with variation in cooling rate. The contributions from elastic and plastic deformation mechanisms on strain are also considered and additional experimental results are shown on the microstructure of an Al particle. Focused ion beam milling of an Al particle to electron transparency was combined with transmission electron microscope imaging in order to examine the microstructure of the Al particles. This confirmed that the Al microparticles have a polycrystalline structure shown by grains all exceeding 100 nm in size.