Combustion characteristics of Al/PTFE materials with different microstructures

The microstructures play a crucial role in the combustion of aluminum/polytetrafluoroethylene (Al/PTFE) materials. Mechanically activated Al/PTFE typically demonstrates higher reactivity but a lower combustion rate compared to physically mixed Al/PTFE. Recently, the combustion performance of fuel-rich Al/PTFE has been well explained by the microexplosion mechanism. In this study, the combustion characteristics of stoichiometric Al/PTFE (26.5:73.5 wt%) materials with varying microstructures were investigated to further the understanding of their combustion mechanism and offer insights for their potential applications in metal cutting. The Al/PTFE materials with different microstructures were prepared using sonication and ball milling methods. The results of scanning electron microscope (SEM) analysis suggest that the sonicated Al/PTFE (s-Al/PTFE) containing spherical Al particles displayed a loosely dispersed structure, while the milled Al/PTFE (m-Al/PTFE) exhibited a densely layered structure with flake-like Al particles coated by the PTFE matrix. The milled Al/PTFE was found to be mechanically activated. Combustion in quartz tubes was recorded using a high-speed camera and a video. Combustion of s-Al/PTFE demonstrated a high-temperature flame (∼2346 K) and obvious microexplosions featuring hot particles ejection, while combustion of m-Al/PTFE showed a weak flame (∼2037 K) and slow-burning, featuring dense carbon smoke. Increasing the powder density was observed to slightly decrease (∼100 K) flame temperature. Microstructure and phase analysis of combustion products were systematically conducted to elucidate the combustion behaviors. The results suggest that the residue of s-Al/PTFE contained high AlF _3 and low carbon content, whereas the residue of m-Al/PTFE exhibited the opposite condition. The results of the combustion tests suggest that microexplosions promoted the oxidation of hot Al particles and carbon products, consequently leading to a fast reaction, high flame temperature, and enhanced heat transfer capability.