A self-glowing solid material comprises a man-made metal mixture containing at least one rare earth metal and an oxide of iron. The material is inducible by flame initiation to self-glow with yellow-to-red colors (577-to-700 nanometer wavelengths). A stealth tracer ammunition comprises a projectile body having a tip and a base, and a solid pellet disposed in the base. The pellet may be made from the above-mentioned self-glowing solid material or another suitable material. The pellet becomes incandescent as a result of being heated when the ammunition is fired. The incandescent pellet emits a glow observable only from behind when the ammunition travels downrange after being fired. An illuminant comprises a bimodal blend of a man-made metal mixture containing at least one rare earth metal and an oxide of iron. The bimodal blend is a blend of smaller-sized fragments and larger-sized pellets. The illuminant is capable of ignition and dispersion in response to ballistic energy to create illumination. An illumination device comprises a body having an interior cavity, the body configured to be launched as a projectile or configured to contain projectiles. An illuminant is disposed in the cavity, the illuminant comprising a bimodal blend of a suitable illuminant material. The illuminant is capable of ignition and dispersion in response to ballistic energy to create illumination.

An example method of preparing spherical composite powders is provided. The method includes introducing one or more starting material powders into an agitation mill. The method includes introducing a process control agent into the agitation mill, the process control agent including at least two immiscible liquids. The method includes agitating and milling the one or more starting material powders and the process control agent with the agitation mill to produce substantially spherical composite powders.

An example method of preparing spherical composite powders is provided. The method includes introducing one or more starting material powders into an agitation mill. The method includes introducing a process control agent into the agitation mill, the process control agent including at least two immiscible liquids. The method includes agitating and milling the one or more starting material powders and the process control agent with the agitation mill to produce substantially spherical composite powders.

Devices for generating a desired gas or mixture of gases by thermally decomposing a polymer, and methods of making and using such devices, are provided. The resulting gas or mixture of gases, or a fraction thereof, can be used for any suitable purpose, including but not limited to use as an inflating or lifting gas. The devices and methods of the disclosure provide greater mass and volumetric efficiency for gas generation and storage relative to conventional gas generation solutions and are safer and simpler than compressed gas cylinders or liquefied gas storage.

A chemical reaction heat source for use in heaters used in down-hole applications is provided. The heat source has a fuel composition that comprises thermite and a damping agent. The use of the thermite mix enables the heaters of the present invention to generate hotter temperatures down wells. This in turn allows the use of Bismuth/Germanium alloys, which have higher melting points, to enable the production of plugs for the abandonment of deeper wells where subterranean temperatures are higher.

A chemical reaction heat source for use in heaters used in down-hole applications is provided. The heat source has a fuel composition that comprises thermite and a damping agent. The use of the thermite mix enables the heaters of the present invention to generate hotter temperatures down wells. This in turn allows the use of Bismuth/Germanium alloys, which have higher melting points, to enable the production of plugs for the abandonment of deeper wells where subterranean temperatures are higher.

A technique facilitates a welding operation in a variety of difficult environments, including downhole environments, to enable formation a dependable connection between components. A tool may be constructed to contain a material mixture used in the welding operation. The tool is conveyed to a position adjacent a weld region of components to be welded together. The material mixture is of a type which may be ignited to initiate a reaction which forms a molten metal from at least one constituent in the material mixture. Additionally, the tool comprises a nozzle oriented to direct the molten metal to the weld region so as to form a secure, welded connection between the components.

A technique facilitates a welding operation in a variety of difficult environments, including downhole environments, to enable formation a dependable connection between components. A tool may be constructed to contain a material mixture used in the welding operation. The tool is conveyed to a position adjacent a weld region of components to be welded together. The material mixture is of a type which may be ignited to initiate a reaction which forms a molten metal from at least one constituent in the material mixture. Additionally, the tool comprises a nozzle oriented to direct the molten metal to the weld region so as to form a secure, welded connection between the components.

A primer includes a layered thermite coating comprising alternating layers of metal oxide and reducing metal (thermite) deposited upon a substrate. The layered thermite coating may include a primary ignition portion adjacent to the substrate, and a secondary ignition portion deposited on the primary ignition portion. The alternating thermite layers may be thinner within the primary ignition portion than in the secondary ignition portion. The primary ignition portion is structured for sensitivity to a firing pin strike to the opposite side of the substrate. The secondary ignition portion is structured to burn at a rate that will ignite smokeless powder or other ignitable substances used in munitions.

A primer includes a layered thermite coating comprising alternating layers of metal oxide and reducing metal (thermite) deposited upon a substrate. The layered thermite coating may include a primary ignition portion adjacent to the substrate, and a secondary ignition portion deposited on the primary ignition portion. The alternating thermite layers may be thinner within the primary ignition portion than in the secondary ignition portion. The primary ignition portion is structured for sensitivity to a firing pin strike to the opposite side of the substrate. The secondary ignition portion is structured to burn at a rate that will ignite smokeless powder or other ignitable substances used in munitions.