Optimization of exploding foil initiator performance through response surface methodology

Exploding Foil Initiators (EFIs) are widely used in explosive systems due to their high reliability and safety. To meet the demands of miniaturization and low energy consumption, this study proposes a framework for optimizing EFI performance using Response Surface Methodology (RSM). A TiW/Ni/Au composite foil was designed and fabricated, and a functional model was established to correlate flyer plate velocity with key geometric parameters: flyer plate thickness, barrel bore diameter, and barrel thickness. Residual analysis and experimental validation demonstrate that the resulting regression model provides reliable predictions of flyer plate velocity across various parameter combinations, exhibiting a mean relative error of merely 2.22%. This approach demonstrates the efficacy of RSM for constrained optimization within defined systems. Analysis of the response model indicated that the flyer plate thickness and barrel bore diameter exert a more pronounced influence on velocity than barrel thickness. The model identified the optimum parameters as a flyer plate thickness of 28.8 μm, a barrel bore diameter of 0.35 mm, and a barrel thickness of 0.46 mm, yielding a predicted flyer plate velocity of 3.715 km/s. Experimental validation recorded an average velocity of 3.730 km/s, and firing tests demonstrated reliable initiation of HNS-IV explosive charges. These results confirm that the proposed RSM framework is a powerful tool for guiding the design and optimization of high-performance EFIs.