Synthesis of Co(OH)F@Al nanobelt array on various substrates for pyro-MEMS

Metastable intermolecular composites (MICs) composed by solid fuel and oxidizer can undergo violent redox reaction with release of huge amount of energy. Integration of MIC with microelectromechanical-system (MEMS) is of particular interest to meet the demand of miniaturization in modern pyrotechnic devices. Meanwhile, fluorine-containing oxidizers are favored in MIC owing to their potential to fluorinate the oxide passivation layer in common elemental fuels. Herein, Co(OH)F was employed for the first time as a novel fluorine-containing oxidizer in Al-based MIC. Vertically aligned Co(OH)F@Al nanobelt arrays (NAs) with tunable morphology were successfully fabricated on a variety of substrates (Si, glass, Ni, Cu, Ti) via a facile hydrothermal synthesis followed by electron beam evaporation. The whole fabrication process is highly compatible with modern MEMS technology. The thermal behavior of pure Co(OH)F and Co(OH)F@Al composites was comprehensively investigated by TG-DSC and a series of ex-situ and in-situ characterization. It was found that, Co(OH)F@Al composites achieved main exothermal reaction before melting of Al regardless of morphology and equivalence ratio. This feature is attributed to the etching of Al₂O₃ shell by HF released from Co(OH)F which is termed as pre-ignition reaction. To elucidate the effect of micro-structure on the actual specific heat release, we proposed a phenomenological model which can be a reference for future micro-structure design of MIC. © 2023 Elsevier B.V.