Thermite mixtures shaped or cast into a desired solid form and having sufficient structural integrity to withstand rough handling and challenging operating conditions, and methods of making such solid forms, are provided. When reacted, the thermite mixtures advantageously produce little or no offgas. The solid thermite forms may further include other materials that confer advantageous physical or chemical properties before, during, or after reaction of the thermite mixture.

Disclosed are a nanoenergetic material composite-based solid propellant, a method of preparing the same, and a projectile using the same. The propellant includes: potassium nitrate-sucrose (KNSU) composite powder; and nanoenergetic material (nEM) composite powder in a solid powder form mixed with the KNSU composite powder to prepare a KNSU/nEM propellant. The method includes: preparing KNSU composite powder; preparing nEM composite powder; and preparing a KNSU/nEM propellant by mixing the KNSU composite powder and the nEM composite powder in a solid powder form. The projectile includes: a clay block; a clay nozzle responsible for releasing the pressure generated by explosion of a propellant; and a propellant lamination area disposed between the clay block and the clay nozzle. Upon ignition of the KNSU/nEM propellant, the nEM composite powder increases the combustion rate and combustion temperature of a potassium nitrate-sucrose (KNSU) propellant.

Disclosed are a nanoenergetic material composite-based solid propellant, a method of preparing the same, and a projectile using the same. The propellant includes: potassium nitrate-sucrose (KNSU) composite powder; and nanoenergetic material (nEM) composite powder in a solid powder form mixed with the KNSU composite powder to prepare a KNSU/nEM propellant. The method includes: preparing KNSU composite powder; preparing nEM composite powder; and preparing a KNSU/nEM propellant by mixing the KNSU composite powder and the nEM composite powder in a solid powder form. The projectile includes: a clay block; a clay nozzle responsible for releasing the pressure generated by explosion of a propellant; and a propellant lamination area disposed between the clay block and the clay nozzle. Upon ignition of the KNSU/nEM propellant, the nEM composite powder increases the combustion rate and combustion temperature of a potassium nitrate-sucrose (KNSU) propellant.

An energetic nanocomposite includes fuel nanoparticles and oxidizer nanoparticles covalently bonded to negatively charged functionalized graphene sheets. A preferred example includes Al fuel nanoparticles and Bi.sub.2O.sub.3 nanoparticles. A preferred method of formation mixes a solution of positively charged fuel nanoparticles, positively charged oxidizer nanoparticles, and negatively charged functionalized graphene sheets having functional groups to bond with the positively charged fuel nanoparticles and positively charged oxidizer nanoparticles. Self-assembly of the energetic nanocomposite is permitted over a predetermined time via the attraction and aggregation of the positively charged fuel nanoparticles positively charged oxidizer nanoparticles and negatively charged functionalized graphene sheets. Additional methods and nanocomposites include unfunctionalized graphene sheets, which can be commercial grade sheets.

An energetic nanocomposite includes fuel nanoparticles and oxidizer nanoparticles covalently bonded to negatively charged functionalized graphene sheets. A preferred example includes Al fuel nanoparticles and Bi.sub.2O.sub.3 nanoparticles. A preferred method of formation mixes a solution of positively charged fuel nanoparticles, positively charged oxidizer nanoparticles, and negatively charged functionalized graphene sheets having functional groups to bond with the positively charged fuel nanoparticles and positively charged oxidizer nanoparticles. Self-assembly of the energetic nanocomposite is permitted over a predetermined time via the attraction and aggregation of the positively charged fuel nanoparticles positively charged oxidizer nanoparticles and negatively charged functionalized graphene sheets. Additional methods and nanocomposites include unfunctionalized graphene sheets, which can be commercial grade sheets.

Compositions comprising magnesium nanoparticles, a nanoscale metal or metalloid, and an oxidizer and methods of fabrication the compositions are described. One example use of such compositions is in high energy fuel applications. One example method includes fabricating a composite by adding magnesium nanoparticles to a composition of a nanoscale metal or metalloid and an oxidant. Examples of the composition resulting from the described processes provides shorter burn times and a multi-fold increase in reactivity compared to the corresponding composition comprising the same amount of nanoscale metal or metalloid and oxidizer but without the magnesium nanoparticles.

Compositions comprising magnesium nanoparticles, a nanoscale metal or metalloid, and an oxidizer and methods of fabrication the compositions are described. One example use of such compositions is in high energy fuel applications. One example method includes fabricating a composite by adding magnesium nanoparticles to a composition of a nanoscale metal or metalloid and an oxidant. Examples of the composition resulting from the described processes provides shorter burn times and a multi-fold increase in reactivity compared to the corresponding composition comprising the same amount of nanoscale metal or metalloid and oxidizer but without the magnesium nanoparticles.

A metal magnalium thermite pellet for creating heated gas is presented. The metal magnalium thermite pellet is insertable into a cutting apparatus and/or a high power igniter that releasably secures to the cutting apparatus. The cutting apparatus for radially projecting a flow of heated gas to cut from an internal surface through an external surface of a conduit for oil, gas, mining, and underwater pressure sealed tool applications. The metal magnalium thermite pellet comprises a metal magnalium thermite composition consisting of between 1 to 44 percent magnalium alloy, between 1 to 44 percent aluminum, between 40 to 60 percent iron oxide, and between 10 to 20 percent polytetrafluoroethylene.

A metal magnalium thermite pellet for creating heated gas is presented. The metal magnalium thermite pellet is insertable into a cutting apparatus and/or a high power igniter that releasably secures to the cutting apparatus. The cutting apparatus for radially projecting a flow of heated gas to cut from an internal surface through an external surface of a conduit for oil, gas, mining, and underwater pressure sealed tool applications. The metal magnalium thermite pellet comprises a metal magnalium thermite composition consisting of between 1 to 44 percent magnalium alloy, between 1 to 44 percent aluminum, between 40 to 60 percent iron oxide, and between 10 to 20 percent polytetrafluoroethylene.

A plug for plugging wells, and in particular oil and gas wells, is provided. The plug has a plug body formed from an outer metal tube of a reduced thickness. The plug also has reinforcement means, attached to an inner surface of the outer tube, that give the plug a cross-sectional structural strength that is at least equivalent to that of a thicker metal tube. The plug has a central heater receiving void located along the axis of the plug to enable a plug deployment heater to be received therein. Also provided is a plug assembly with a variable cross-sectional area in a plane perpendicular to the plane in which the assembly is deployed during the plugging of underground conduits.