Fabrication and characterization of the Ni–Al energetic structural material with high energy density and mechanical properties

The fully dense Ni–Al energetic structural material (ESM) was successfully fabricated by using shock consolidation, with no reaction between the constituents. The microstructure, quasi-static and dynamic compressive behavior and energetic characteristics were investigated. The results revealed a uniform microstructure along the cross-section and both phases were continuously distributed. No intermetallic was detected by the XRD and a 5 nm thick interlayer composed of amorphous phase and crystalline phase was observed at the Ni–Al interface by TEM. The interfacial strength was shown to have a strong effect on the ductility and the strength of Ni–Al ESM, and could be significantly improved by solid-state diffusion during the shock loading and the following heat-treatment. After heat-treatment the samples showed a high quasi-static compressive strength of 300 MPa and a ductility of 14.5%. At impact velocity above 671 m/s, the Ni–Al ESM was initiated and released a large amount of rising the shock temperature or energy. Its reaction efficiency strongly depends on the impact velocity. The good mechanical properties and energetic characteristics of the Ni–Al ESM shows a great potential for the shock consolidation in fabrication of metallic energetic structural materials.