Thermite-for-Demise (T4D): Charge Shaping Exploratory Tests

Thermite-for-Demise (T4D) is an innovative approach to aid spacecraft demise during re-entry by leveraging thermite-based materials to enhance structural demisability. This study investigates the initial steps in developing thermite-based materials tailored for Design-for-Demise (D4D) applications. Two fabrication techniques were explored: pelletization of thermite powders with or without polymeric binders and embedding thermite in a polymer matrix for casting. The pelletization of fuel rich thermite formulations, with the addition of polymeric binders resulted in lower porosity. However, compression tests revealed the mechanical limitations and variability of the produced pellets, emphasizing the necessity for further processing to improve the mechanical performances. Thermite dispersion in acrylonitrile butadiene styrene (ABS) demonstrated promising pyrotechnic behavior at thermite concentrations equal or higher than 15%. This work establishes a foundation for future exploration of thermite-based structural reactive materials to mitigate ground casualty risks due to spacecraft uncontrolled re-entry.