The combustion mechanism of aluminum (Al) particles depends
on
the alumina (Al2O3) passivation layer surrounding
the metal core. Hydrating Al2O3 into bayerite
(Al(OH)3) can alter the interfacial reactions and energy
conversion behavior of the metal fuel particles. This study explores
chemical weathering of the surface of micron-sized aluminum (μAl)
particles using temperature and time in solution as parameters for
shell hydration in aqueous suspensions. Using X-ray diffraction, microscopy,
spectroscopy, and thermal analysis, the formation of an Al(OH)3 shell is confirmed on μAl particles with greater than
96 wt % Al core retained. A detailed mechanism for surface hydration
is discussed. The hydrated metal particles were then evaluated as
a potential solid composite propellant fuel. Burn rate experiments
were performed in a windowed pressure vessel, and condensed phase
combustion products were recovered. Results show that the burn rate
of hydrated μAl (1.068 cm/s) is 17.75% higher compared to standard
μAl (0.907 cm/s) at 10.34 MPa with hydrated μAl showing
a clear particle suspension entrained near the burning surface. The
hydrated shell enables oxidizing gas generation in proximity to the
exposed Al core contributing to more complete combustion and accelerated
burn rates at higher pressures. The solution-based hydration technique
alters interface properties and affects the reaction mechanism and
combustion demonstrated for propulsion applications.