Fabrication of tetrapod-shaped Al/Ni microparticles with tunable self-propagating exothermic function

This paper reports micron-sized tetrapod shape Al/Ni particles fabricated by injection molding and electroless plating. We realize fabricating the 3D tetrapod micro particles with self-propagating exothermic function that is able to tunable by changing Al powder's diameter and simultaneously by keeping porous Al tetrapod's void fraction constant. The maximum surface temperature and high temperature duration during the reaction differ from sputtered Al/Ni multilayer film's exothermic performances. The tetrapod's exothermic performances can be freely controlled in response to the applications.