Additively Manufactured Thermite-Based Energetics

ADDITIVELY MANUFACTURED THERMITE-BASED ENERGETICS: CHARACTERIZATION AND APPLICATIONS By Kelsay Neely Dissertation Submitted to the Faculty of the Graduate School of Vanderbilt University In partial fulfillment of the requirements For the degree of DOCTOR OF PHILOSOPHY in Mechanical Engineering May 8, 2020 Nashville, Tennessee Approved: Alvin M. Strauss, Ph.D. Kevin C. Galloway, Ph.D. Kelsey B. Hatzell, Ph.D. Kenneth Frampton, Ph.D. Kenneth Pence, Ph.D. ACKNOWLEDGEMENTS This dissertation is the culmination of several years of work. I’d like to thank my advisor Dr. Alvin Strauss for his guidance on my academic career, my professional career, and this project. Similarly, I’d like to thank Dr. Kevin Galloway for all of his feedback and for helping me develop as a researcher and as an academic. I also appreciate the rest of my committee, Dr. Ken Frampton, Dr. Ken Pence, and Dr. Kelsey Hatzell for their advice and feedback on my dissertation. I’d like to thank all of my lab mates, specifically my unwavering safety buddies Adam Jarrell, Connor Strawn, Lucas Wilkins, Ben Snyder, Brayden Terry, and Jake Matthews. Finally, I’d like to thank the Tennessee Space Grant Consortium for funding me as a NASA Space Grant Fellow, and the Naval Sea Systems Command (NAVSEA) for funding me and my work through the Naval Engineering Education Consortium (NEEC). On a personal note, there are a lot more people I need to thank, way too many to mention here but I’ll try. I couldn’t have done this without the unwavering support of my friends. I’d like to thank Darren Tinker, Dylan Shane, Melissa, Tyler, and Bella Keagle, and Chase Mu for keeping me from constantly working all the time. I have to acknowledge that I couldn’t have done this without the extensive love and support of my family. I’m eternally grateful to Courtney Mason and Forrest Edens for their unwavering support and encouragement at all times. Finally, I could not have started this degree, let alone completed it, without the love and support of my parents, Bill and Janet. ii TABLE OF CONTENTS Page ACKNOWLEDGEMENTS .................................................................................................................... i LIST OF TABLES ............................................................................................................................. vi LIST OF FIGURES .......................................................................................................................... vii CHAPTER I. INTRODUCTION ..............................................................................................................1 Literature Review ..........................................................................................................1 Additive Manufacturing .................................................................................................2 Additive Manufacturing of Highly Viscous Materials ..................................................6 Reactive Material Architectures ..................................................................................13 Reactive Material Architecture Applications...............................................................17 II. ADDITIVELY MANUFACTURED REACTIVE MATERIAL ARCHITECTURES AS A PROGRAMMABLE HEAT SOURCE ................................................................................22 Abstract ........................................................................................................................22 Introduction ..................................................................................................................22 Materials and Methods .................................................................................................24 Results ..........................................................................................................................30 Discussion ....................................................................................................................32 Conclusion ...................................................................................................................38 Acknowledgements ......................................................................................................38 Author Disclosure Statement .......................................................................................38 Reference .....................................................................................................................38 III. MULTI-MATERIAL ADDITIVELY MANUFACTURED COMPOSITE ENERGETICS VIA CONTINUOUS FILAMENT DIRECT INK WRITING ........................................................41 Abstract ........................................................................................................................41 Introduction ..................................................................................................................41 iii Methods and Materials .................................................................................................42 Results and Discussion ................................................................................................44 Conclusions ..................................................................................................................53 Acknowledgments........................................................................................................54 References ....................................................................................................................54 IV. SOLDERED COPPER LAP JOINTS USING REACTIVE MATERIAL ARCHITECTURES AS A HEAT SOURCE ..........................................................................................................57 Abstract ........................................................................................................................57 Introduction ..................................................................................................................57 Methods........................................................................................................................58 Results and Discussion ................................................................................................62 Conclusion ...................................................................................................................64 Funding ........................................................................................................................64 References ....................................................................................................................65 V. ADDITIVELY MANUFACTURED REACTIVE MATERIAL ARCHITECTURES FOR EXOTHERMIC BRAZING ..............................................................................................67 Abstract ........................................................................................................................67 Introduction ..................................................................................................................67 Methods & Materials ...................................................................................................69 Results & Discussion ...................................................................................................71 Conclusion ...................................................................................................................78 Acknowledgements ......................................................................................................78 References ....................................................................................................................79 VI. CHEMICAL EQUILIBRIUM SIMULATIONS ....................................................................81 Introduction ..................................................................................................................81 Tested Thermite Compositions ....................................................................................81 Adiabatic Flame Temperature and Reaction Rate .......................................................82 Phase Changes .............................................................................................................89 Products........................................................................................................................92 Conclusion ...................................................................................................................94 iv VII. CONCLUSIONS AND FUTURE WORK ............................................................................95 Conclusions ..................................................................................................................95 Future Work .................................................................................................................99 REFERENCES ................................................................................................................................101 APPENDIX A: G-CODE .................................................................................................................105 v LIST OF TABLES Table Page 1. Table showing ASTM defined AM process categories, technology examples, and materials. Adapted from [2]. ................................................................................................2 2. Tested dimensions for architecture 2 as depicted in Figure 16b. Four iterations of architecture 2 were tested, with different

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