Sputter-deposited Al/CuO multilayers exhibit fast combustion reactions in which an exothermic chemical reaction wavecontrolled by the migration of oxygen atoms from the oxide matrix toward the aluminum layers through interfacial layersmoves throughout the multilayer at subsonic rates (meters per second to tens of meters per second). We directly observed the structural and chemical evolution of Al/CuO/Al multilayers upon heating to 700 °C using high-magnification transmission electron microscopy (TEM) and scanning TEM, providing simultaneous subnanometrer imaging resolution and detailed chemical analysis. Interestingly, as deposited, the trilayer is characterized by two distinct interfacial layers: 4.1 ± 0.2 nm thick amorphous alumina and a 15 ± 5 nm thick mixture of AlO x and Cu x Al y O z , at the bottom interface and top interface, respectively. Upon heating, we accurately characterized the evolving nature and structure of these interfaces, which are rapidly replaced by the reaction terminal oxide (Al 2 O 3 ). For the first time, we unraveled the release of gaseous O from the sparse columnar and defective CuO well below reaction onset (at ∼200 °C) which accumulates at interfaces and contributes to initiate the Al oxidation process at the vicinity of native interfaces. The oxidation process is demonstrated to be accompanied by a continuous densification and modification of the CuO layer. Between 300 and 350 °C, we observed a brutal shrinkage of the CuO layer (14% loss of its initial thickness) leading to the mechanical fracture in the top alumina growing layer. Consequently, this latter becomes highly permeable to oxygens leading to a brutal enhancement of the oxidation rate (×4). We also characterized stressed-induced interfacial delamination at 500 °C pointing clearly to the mechanical fragility of the top interface after the CuO transformation. Altogether, these results permit one to establish a multistep reaction scenario in Al/CuO sputter-deposited films supporting to an unprecedented level a mechanistic assignation of differential scanning calorimetry peaks. This study offers potential benefits for the development of aging models enabling the virtual prediction of the calorimetric response of exothermic Al/CuO thin-film reactions.

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The ignition of Al/CuO multilayered material is studied experimentally to explore the effect of heating surface area, layering and film thickness on the ignition characteristics and reaction performances. After the description of the micro-initiator devices and ignition conditions, we show that the heating surface area has to be properly calibrated to optimize the nanothermite ignition performances. We demonstrated experimentally that a heating surface area of 0.25 mm 2 is sufficient to ignite a multilayered thermite film of 1.6 mm wide by a few cm long, with a success rate of 100%. A new analytical and phenomenological ignition model based on atomic diffusion across layers and thermal exchange is also proposed. This model considers that CuO first decomposes into Cu 2 O, the oxygen diffusing across Cu 2 O and Al 2 O 3 layers before reaching the Al layer where it reacts to form Al 2 O 3 . The theoretical results in terms of ignition response times confirm the experimental observation. The increase of the heating surface area leads to an increase of the ignition response time and ignition power threshold (go/no go condition). We also evidence that for any heating surface area, the ignition time rapidly decreases when the electrical power density increases until an asymptotic value, named minimum response ignition time, which is a characteristic of the multilayered thermite itself. At the stoichiometric ratio (Al thickness is half of CuO one), the minimum ignition response time can be easily tuned from 59 µs to 418 ms by tuning the heating surface area. The minimum ignition response time increases when the bilayer thickness increases. Not only this work gives a set of micro-initiator design rules to obtain the best ignition conditions and reaction performances but it also details a reliable and robust MEMS process to fabricate igniters and it brings new understanding of phenomena governing the ignition process of Al/CuO multilayers.

The complex Al/CuO self-propagating reaction involving multi-phase and multi-species dynamics was studied in order to investigate the very high flame temperature around the vaporization temperature of alumina, even under a neutral environment. Experiments were performed on different sputter-deposited Al/CuO multilayers coupling optical spectroscopy with high speed camera measurements. The clear presence of both AlO and Al signatures in gas phase suggests that the redox reaction starts in the bulk nanolaminate, which then rapidly tear off the substrate to continue burning in a heterogeneous (condensed and gas) phase in the environment. The flame temperature increases with the stoichiometry but is independent of the bilayer thickness. In addition to the confirmation of the effects of stoichiometry and the bilayer thickness on the characteristics of the self-propagating reaction, the predominant role of

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