A Study on the Thermal Behaviour of Micron-Sized Aluminium Powder in Contact with Water

Aluminium powder, an energetic material, is prone to thermal runaway upon water exposure under local heat sources, yet the nonadiabatic mechanisms of micron-sized accumulated aluminium powder under localised heating remain unclear. This study employs a proprietary characterisation platform to investigate the effects of particle size, water content, and local heat source power on heat transfer in the dry state and on parameters including induction time, onset temperature, peak heat release rate, and reaction heat during the induction and main reaction phases. In the dry state, decreasing particle size enhances effective thermal conductivity and accelerates temperature rise, whereas elevated local heat source power exacerbates thermal inertia. Under local heating upon water exposure, reduced particle size significantly enhances reactivity; the reaction heat of 2 μm powder reaches 983 J/g, approximately fourfold that of 106 μm powder. Water content exhibits a nonmonotonic effect, with the onset temperature reaching a minimum of 66.4 °C at a water content of 25%, while the reaction heat peaks at 33% water content. Interestingly, increasing local heat source power was found to suppress reaction intensity, and reaction heat at 10 W is one sixth of that at 2.5 W, attributed to rapid product layer densification and the possible steam-film barrier effect shifting the controlling mechanism from chemical to diffusion control. A coupled multifactorial predictive model incorporating the three factors was established with a correlation coefficient R2 of 0.92, providing a theoretical basis and practical guidance for hazard assessment and safe storage of aluminium powder.