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Al–Ni energetic composites, applicable to localized heating, were fabricated from atomized powders and hammer-milled flakes by means of ultrasonic powder consolidation, a novel low-temperature rapid powder consolidation technique. Full-density consolidation was achieved in 1 s of consolidation time at temperatures as low as 573 K without causing appreciable reactions between Al and Ni. The consolidated composite structure consists of Ni powder particles or flakes uniformly distributed in a metallurgically consolidated Al matrix. Consolidated materials were evaluated using spark and continuous-heating ignition tests. Ultrasonic powder consolidation is potentially applicable to the fabrication of a wide range of metastable materials that cannot be processed at elevated temperatures.

Fabrication of micro/nano structured aluminum–nickel energetic composites by means of ultrasonic powder consolidation