A comparative structural and combustion study of Al-MO/PVDF (MO=ZnO & ZnFe2O4) thermites synthesised by electrospraying and mechanical mixing

Aluminised thermites show strong potential for energy-intensive applications, but ensuring stable nanoscale dispersion and optimising combustion performance is challenging. This study prepared Al–MO/PVDF thermites (MO = ZnO, ZnFe₂O₄) by electrospraying and mechanical mixing to compare how particle morphology and compositional uniformity affect reactivity. Electrosprayed samples formed near-spherical, submicron particles with homogeneous distributions of reactants, whereas mechanically mixed samples aggregated into larger, irregular clusters. Differential scanning calorimetry revealed sharper, staged exothermic peaks in the electrosprayed thermites, indicating enhanced reactant contact, while the mechanically mixed thermites produced broad, overlapping exotherms. X-ray diffraction showed partial amorphisation and core-shell formation under rapid solvent evaporation. Laser ignition tests demonstrated faster ignition, higher flame temperatures, and more intense combustion in electrosprayed formulations, particularly Al–ZnFe₂O₄/PVDF, which exhibited a secondary heat release (micro-explosion). Electrospray-assisted fabrication improved homogeneity and promoted rapid, high-temperature reactions for enhanced combustion performance.