The fabrication and characterization of metal-based energetic composite materials are currently being examined for a range of new applications. A newly developed ultrasonic consolidation process is used for the synthesis of Al/Fe2O3 and Al/Cu2O compacts over a wide range of powder ratios at room temperature. Powder consolidation was achieved by a multistep procedure involving simultaneous application of pressure and ultrasonic vibrations. The observed reaction characteristics of the composites are similar to those of previously reported thermite compacts prepared by a traditional powder metallurgy method.
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