Preparation of fine aluminum powders by solution methods

Abstract

Fine aluminum powders are prepared by decomposing alane-adducts in organic solvents under an inert atmosphere to provide highly uniform particles and believed particularly effective as fuels and additives, in pyrotechnics, and in energetic materials. Effective adduct species are trialkyl amines and tetramethylethylenediamine, ethers and other aromatic amines. Effective production is obtained at atmospheric pressure and at temperatures as low as 50° C. with xylene solvent. Toluene, dioxane, and tetramethylethylenediamine were also effective solvents. Aliphatic solvents and other aromatic and polar solvents are believed effective. Titanium catalyst was provided as a halide, amide, and alkoxide; and it is believed that the corresponding compounds of zirconium, hafnium, vanadium, niobium, and tantalum are effective as catalysts. Particle size was controlled by varying catalyst concentration and by varying the concentration of an adducting species. It is believed that particle size is controllable by varying the catalyst, concentration of the reactants, polarity of the solvent, reaction temperature, and the stage and rate at which the solution is brought to this temperature. The product powder is passivated in the reaction vessel by exposing the solution to air before product separation or by controlling the admission of air to the separated, dried powder.