The thermal behaviour of two different Al nanopowders and a micron‐sized Al powder was studied using DSC, simultaneous TG‐DTA, and accelerating rate calorimetry (ARC). The results show that the reactivity of Al powder increases as the particle size decreases. The thermal stability of the smaller Al nanopowder (Als) in water and in a humid atmosphere was determined using ARC and TG‐DTA, respectively. Atomic Absorption Spectrometry (AAS), X‐Ray Photoelectron Spectrometry (XPS) and Auger Electron Spectrometry (AES) were used to characterize the surface chemistry of Alex. The outgassing behaviour for mixtures of RDX and the various Al powders was investigated using TG‐DTA‐FTIR‐MS. Evolution of NO2 and N2O from a chemical interaction between Al nanopowders and RDX was observed. The effect of Als and Alex on the thermal stability of TNT, RDX, Comp B, and AP was determined using ARC. Addition of Als significantly lowered the onset temperature for TNT and RDX decomposition. Electrostatic discharge (ESD) sensitivities of Al nanopowders and their mixtures with TNT, Comp B, RDX and AP were determined. The results show that the AP/Als mixture is very sensitive to ESD. Standard dust explosibility tests demonstrated that Alex is highly explosible.

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The thermal behaviour in air of two Al nanopowders, Alss and Alsstef, a Teflon coated version of Alss, was determined using DSC, TG-DTA and accelerating rate calorimetry (ARC). Compared to two larger Al nanopowders, for which hazards results have been reported, Alss and Alsstef are less reactive in air, possibly due to the nature of the passivating and coating layers. The stability of Alss and Alsstef in a wet environment was also investigated using ARC. Alss is very reactive with water, which could lead to a problem of aging in a humid atmosphere. The ∫coating∫ of Alsstef significantly reduces the reactivity of Alss with water. Outgassing behaviour of mixtures of ADN, GAP and various Al powders was investigated using TG-DTA-FTIR-MS. No chemical interactions were observed between ADN/Al, GAP/ Al and ADN/GAP. The effect of the addition of Al nanopowders on the thermal decomposition of ADN and GAP was studied using ARC. Al nanopowders had a minor effect on the thermal stability of ADN, while the addition of Alss and Alsstef lowered the onset temperature of GAP. The electrostatic discharge (ESD), impact and friction sensitivities of Al nanopowders and their mixtures with ADN and GAP were also determined. Al nanopowders appear to sensitize ADN to ESD, impact and friction.

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