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I suppose another possibility is that fashioning Al/Si chips might give you more bang for the buck not only by more intimately mixing Al and Si, but that the Si could also essentially function as the oxide layer in the 'planar' dimension. Only the edges would require a normal oxide layer.
As for the "energetic reaction" (page 435)
Figure D-5 shows two superimposed DTA scans. The initial heating scan at 20K/Min exhibits a broad exothermic peak centered at 400ºC
Just before, it is explained how metastable phases can be formed when the metal is cooling, that can be detected using DTA. Upon heating, theses metastable phases can transform,being detectable as exothermic spikes.
From page 434:
Beyond approximately 650ºC (...), a black scale formed between the steel and the paint,Fig. D-3. This scale layer had very poor adherence to the steel, and the paint was seen to flake off with slight pressure. Above approximately 800ºC, the kinetics of the scale formation were very fast, and after short exposures to this temperature a thick scale formed and spalled off the steel, carrying away the paint.
Originally Posted by moorea34
NISTNCSTAR1-3C appendix D p442
Figure D-4...Chips ?
See also table D-1... p438 Iron oxyde ?
Material Safety Data Sheet (MSDS) for Tnemec's Series 010 Red Primer http://www.tnemec.com/resources/product/msds/m10v.pdf
Zinc Compounds - 2.98% by weight
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