Synergistically enhanced thermal and combustion in microfluidic-engineered nano-Al/CuO@F2603 energetic microspheres

Nano-thermite (Al/CuO) exhibits high reactivity and energy density, but its application is often limited by issues such as nanoparticle agglomeration and inhomogeneous mixing. This study presents an innovative strategy that employs microfluidic technology to overcome these challenges. Molecular dynamics simulations identified F2603 as an optimal binder for improving interfacial stability. By precise regulation of multiphase flow within microchannels, Al/CuO@F2603 composite microspheres were successfully fabricated, featuring excellent dispersibility, high sphericity, and strong hydrophobicity. Among formulations with varying aluminum content (30%, 40%, and 50%), the Al/CuO@F2603-2 sample (containing 40% Al) demonstrated superior performance. Specifically, its initial exothermic peak occurred approximately 200 °C lower than that of raw Al powder, achieving a maximum heat release of 1929.8 J/g and a unique deflagration phenomenon. Constant-volume combustion tests further confirmed its exceptional reactivity, showing an ignition delay of 0.157 s, a 43 ms combustion duration, a peak pressurization rate of 5.633 MPa/s, and an ignition energy of 4.472 J. This enhanced performance is attributed to the near-stoichiometric Al/CuO thermite reaction combined with a pre-ignition reaction (PIR) between the binder and aluminum. Overall, this work provides valuable theoretical guidance for designing advanced energetic composites with high reactivity, hydrophobicity, and sphericity.