Combustion synthesis/micropyretic synthesis is a technique in which material synthesis is accomplished by the propagation of a combustion front across the sample. In some cases, the combustion front may propagate in an unstable mode where the propagation velocity and combustion temperature of the combustion front are altered periodically. In this study, the processing conditions leading to unstable combustion reaction were first studied theoretically. The boundary temperatures separating stable and unstable reactions were then determined. The numerical analysis showed that the combustion temperature and the propagation velocity changed periodically during unstable combustion. As the combustion reaction became unstable, the average propagation velocity and the oscillatory frequency of front propagation decreased. The products of unstable combustion synthesis possessed the banded structures, implying the occurrence of the unstable oscillatory propagation, as demonstrated experimentally. In this study, high activation energy combustion (Ti + 2B reaction) and low activation energy combustion (Ni + Al reaction) were both chosen to illustrate the effect of unstable combustion. It is the first time the experimental and numerical results were combined to investigate the temperature and propagation velocity variations during unstable combustion.

Banded structures in combustion-synthesized products have been observed during unstable combustion synthesis. The formation of the banded structures is discussed in this article. It is noted that the band spacing was changed when several initial processing conditions were varied. Any change in the processing parameters that correspondingly caused more unstable combustion was observed to decrease the propagation velocity of the combustion front and increase the band spacing. The correlation of the band spacing and oscillatory frequency of the unstable oscillatory combustion with the propagation velocity was also discussed. From the results studied in this work, it is noted that the change of the band spacing can be used to infer the degree of the instability of the combustion front.

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Energy-efficient processing of TiB compound with nanowhiskers by micropyretic synthesis is investigated in this paper. Micropyretic synthesis not only offers shorter processing time but also excludes the requirement for high-temperature sintering and it is considered as the one of the novel energy-saving processing techniques. Experimental study and numerical simulation are both carried out to investigate the correlation of the processing parameters on the microstructures of the micropyretically synthesized products. The diffusion-controlled reaction mechanism is proposed in this study. It is noted that nanosize TiB whiskers only occurred when the combustion temperature is lower than the melting point of TiB but higher than the extinguished temperature. The results generated in the numerical calculation can be used as a helpful reference to select the proper route of processing nanosize materials. The Arrhenius-type plot of size and temperature is used to calculate the activation energy of TiB reaction. In addition to verifying the accuracy of the experimental measures, the reaction temperature for producing the micropyretically synthesized products with nanofeatures can be predicted.