Embodiments directed to a method of manufacturing a pyrotechnic article for use with a thermal battery are disclosed. The method includes forming an iron oxide preform from iron oxide powder. The method also includes reducing the iron oxide preform to an iron preform made of metallic iron. The method further includes impregnating the iron preform with an oxidizer to form the pyrotechnic article.

Embodiments directed to a method of manufacturing a pyrotechnic article for use with a thermal battery are disclosed. The method includes forming an iron oxide preform from iron oxide powder. The method also includes reducing the iron oxide preform to an iron preform made of metallic iron. The method further includes impregnating the iron preform with an oxidizer to form the pyrotechnic article.

A reduced toxicity baseline screening smoke composition and method includes a mixture of lithium perchlorate and boron. The mixture may further include a burn rate modifier and any of an inorganic chloride coolant and a carbonate coolant. The lithium perchlorate may be in the range of 75% to 95% parts by weight. The boron may be in the range of 5% to 25% parts by weight. The any of an inorganic chloride coolant and a carbonate coolant may be in the range of 5% to 25% parts by weight. The mixture may include boron oxide.

A reduced toxicity baseline screening smoke composition and method includes a mixture of lithium perchlorate and boron. The mixture may further include a burn rate modifier and any of an inorganic chloride coolant and a carbonate coolant. The lithium perchlorate may be in the range of 75% to 95% parts by weight. The boron may be in the range of 5% to 25% parts by weight. The any of an inorganic chloride coolant and a carbonate coolant may be in the range of 5% to 25% parts by weight. The mixture may include boron oxide.

A gas generator is provided, the gas generator having a propellant cushion that prevents movement of propellant tablets or grains by providing a bias thereagainst. Furthermore, the cushion is formed from an auto-igniting material thereby functioning not only as a cushion, but also as an enhanced auto-ignition charge.

A gas generator is provided, the gas generator having a propellant cushion that prevents movement of propellant tablets or grains by providing a bias thereagainst. Furthermore, the cushion is formed from an auto-igniting material thereby functioning not only as a cushion, but also as an enhanced auto-ignition charge.