Thermite-Metal Foam

Abstract

The present invention discloses materials, systems and methods for creating metal foams to envelop targets, which involve the formulation of powdered thermite/metal matrices. Essentially, each matrix will include thermite and a foaming agent. Additionally, a thickening agent can be blended into the powdered thermite/metal matrix to create desirable foaming properties when the thermite is ignited. A heat sink agent can also be dispersed throughout the powdered thermite/metal matrix to limit temperature rise in the matrix during a thermite reaction. Further, a binder can be combined with the powdered thermite/metal matrix to hold the formulation together. In use, the formulation is delivered to the vicinity of the target where it is ignited. The resultant metal foam is intended to envelop and neutralize the target.

1 . A system for creating a metal foam to envelop a target, the system including a formulation for creating the metal foam which comprises:
 thermite; and   a foaming agent positioned with the thermite and responsive thereto to create the metal foam.   
     
     
         2 . A system as recited in  claim 1  wherein the foaming agent is admixed with the thermite to create a powdered thermite/metal matrix. 
     
     
         3 . A system as recited in  claim 1  further comprising a thickening agent positioned with the powdered thermite/metal matrix to facilitate action of the foaming agent upon an ignition of the thermite. 
     
     
         4 . A system as recited in  claim 3  wherein the thickening agent is selected from a group consisting of SiC, Al 2 O 3  and MgO. 
     
     
         5 . A system as recited in  claim 1  further comprising a heat sink agent positioned with the powdered thermite/metal matrix. 
     
     
         6 . A system as recited in  claim 5  wherein the heat sink agent is TiC. 
     
     
         7 . A system as recited in  claim 1  further comprising a binder combined with the powdered thermite/metal matrix for holding the formulation together. 
     
     
         8 . A system as recited in  claim 7  wherein the binder is selected from a group consisting of KBr, NaBr, CaBr 2  and S. 
     
     
         9 . A system as recited in  claim 1  wherein the thermite comprises aluminum and iron oxide mixed in a weight ratio of approximately 8:3. 
     
     
         10 . A system as recited in  claim 1  wherein the foaming agent is selected from a group consisting of FeO+C, SrCO 3 , VO 2 +C, Cr 2 O 3 +C, MnO+C and TiH 2 . 
     
     
         11 . A system as recited in  claim 1  wherein the thermite includes a fuel component and an oxidant, wherein the fuel component is selected from a group consisting of Mg, Ca, Ti, Zn, Si and B, and wherein the oxidant is selected from a group consisting of B 2 O 3 , SiO 2 , Cr 2 O 3 , MnO 2  and CuO. 
     
     
         12 . A system as recited in  claim 1  further comprising:
 an igniter for initiating a reaction in the formulation to create the metal foam; and 
 a canister for holding the formulation and the igniter during deployment of the system to the target. 
 
     
     
         13 . A system for neutralizing a target which comprises:
 a powdered matrix formulation containing thermite and a foaming agent;   an igniter for initiating a reaction in the formulation to create a metal foam for enveloping the target; and   a canister for holding the formulation and the igniter during deployment of the system to the target.   
     
     
         14 . A system as recited in  claim 13  wherein the formulation further comprises:
 a thickening agent; 
 a heat sink agent; and 
 a binder. 
 
     
     
         15 . A system as recited in  claim 13  wherein the target is selected from a group comprising chemical/biological agents, weapons and facilities. 
     
     
         16 . A system as recited in  claim 13  wherein the igniter initiates the reaction with a magnesium spark. 
     
     
         17 . A system as recited in  claim 13  wherein the thermite comprises aluminum (Al) and an iron oxide selected from a group consisting of Fe 2 O 3  and Fe 3 O 4 , and further wherein the aluminum and iron oxide are mixed with approximately equal volumes. 
     
     
         18 . A method for neutralizing a target which comprises the steps of:
 delivering a powdered thermite/metal matrix formulation proximate the target;   igniting the powdered formulation to generate a molten metal;   expanding the molten metal with a foaming agent to establish a molten metal foam for enveloping the target; and   freezing the molten metal to create a solid metal foam for enveloping the target.   
     
     
         19 . A method as recited in  claim 18  wherein the thermite/metal matrix comprises aluminum (Al) and an iron oxide selected from a group consisting of Fe 2 O 3  and Fe 3 O 4 , and wherein the aluminum and iron oxide are mixed with approximately equal volumes. 
     
     
         20 . A method as recited in  claim 18  further comprising the step of blending a thickening agent into the powdered thermite/metal matrix to facilitate action of the foaming agent upon an ignition of the thermite. 
     
     
         21 . A method as recited in  claim 18  further comprising the step of dispersing a heat sink agent throughout the powdered thermite/metal matrix to control temperature rise therein. 
     
     
         22 . A method as recited in  claim 18  further comprising the step of combining a binder with the powdered formulation to hold the formulation together. 
     
     
         23 . A combination of materials for creating a metal foam to envelop a target, the materials comprising:
 thermite; and   a foaming agent positioned with the thermite and responsive thereto to create the metal foam.   
     
     
         24 . A combination of materials as recited in  claim 23  wherein the foaming agent is admixed with the thermite to create a powdered thermite/metal matrix. 
     
     
         25 . A combination of materials as recited in  claim 23  further comprising a thickening agent positioned with the powdered thermite/metal matrix to facilitate action of the foaming agent upon an ignition of the thermite. 
     
     
         26 . A combination of materials as recited in  claim 25  wherein the thickening agent is selected from a group consisting of SiC, Al 2 O 3  and MgO. 
     
     
         27 . A combination of materials as recited in  claim 23  further comprising a heat sink agent positioned with the powdered thermite/metal matrix. 
     
     
         28 . A combination of materials as recited in  claim 27  wherein the heat sink agent is TiC. 
     
     
         29 . A combination of materials as recited in  claim 23  further comprising a binder combined with the powdered thermite/metal matrix for holding the formulation together. 
     
     
         30 . A combination of materials as recited in  claim 29  wherein the binder is selected from a group consisting of KBr, NaBr, CaBr 2  and S. 
     
     
         31 . A combination of materials as recited in  claim 23  wherein the thermite comprises aluminum and iron oxide mixed in a weight ratio of approximately 8:3. 
     
     
         32 . A combination of materials as recited in  claim 23  wherein the foaming agent is selected from a group consisting of FeO+C, SrCO 3 , VO 2 +C, Cr 2 O 3 +C, MnO+C and TiH 2 . 
     
     
         33 . A combination of materials as recited in  claim 23  wherein the thermite includes a fuel component and an oxidant, wherein the fuel component is selected from a group consisting of Mg, Ca, Ti, Zn, Si and B, and wherein the oxidant is selected from a group consisting of B 2 O 3 , SiO 2 , Cr 2 O 3 , MnO 2  and CuO.