Substitution of aluminum for Magnesium as a Fuel in FlaresBossie Jackson and Frnak Taylor et al.4th International Pyrotechnics Seminar 1974ABSTRACTA formulation has been developed for use in the U.S. Army Trip Flare whichutilizes aluminum as a substitute for magnesium fuel. Previously aluminum wasnot considered to be a good fuel for flare applications since mixtures of atomizedaluminum (diameter [greater than or equal to] 15 micron and sodium nitrate arenot readily ignitable, propagate poorly, and burn very erratically andinefficiently.one of the reasons for the inefficiency of this system is the considerable loss offuel as incandescent particles. This Roman Candle effect makes the flare anincendiary device as well as an illumination source. This incendiary aspect isvery undesirable causing possible harm to users and danger of starting groundfires. The present study shows how the ignition properties of aluminum sodiumnitrate can be significantly improved and how the production of incandescentparticles can be minimized by using small percentages of various additives, suchas tungsten metal.By using these new additive systems, the two basic advantages ofaluminum can be used. The first is cost, 38 cents per pound for aluminum ascompared to 85 cents for 20/50 mesh atomized magnesium, and the second isits ready availability.The disadvantages associated with the present aluminum formulation, aswell as with other aluminum formulations, when exposed to excess moisture aregassing and self-heating leading to spontaneous ignition in storage.Experimental data is presented showing these interesting phenomena. Bycareful exclusion of moisture during processing, these effects can be eliminated,as was demonstrated by long term storage stability testing.INTRODUCTIONThe present study was conducted to determine if a composition could bedeveloped for the Army M49A1 Trip Flare containing aluminum as a substitutefor magnesium. The primary justification for this program was based on cost andavailability of aluminum as opposed to magnesium. Atomized magnesiumpowder is primarily produced for pyrotechnic applications, while powderedaluminum is mass produced for a host of applications ranging from pigments inpaints to energy constituents in propellants and explosives.Although the present study is directed primarily towards the Trip Flare, itdelves into all aspects of flare technology. For example, investigations weremade of the effects of particle size, fuel-oxidant ratio, binder concentration,additives, fuel coating, flare case materials, flare case coatings, moisture, andshort and long-term stability.Previously aluminum was not considered to be a good fuel for flareapplications since mixtures of atomized aluminum (diameter greater than orequal to 15 micron) and sodium nitrate ignite poorly, propagate poorly, and bumvery erratically and inefficiently. One of the reasons for the inefficiency of theAl-NaN03 system is that it produces a profusion of incandescent particles. ThisRoman Candle effect makes the flare an incendiary device as well as anillumination source. This incendiary aspect is very undesirable -- causing
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