Abstract
<jats:p>Al-NiO thermites are recognized for their high energy density, low gas emission, and stable at normal conditions, making them ideal for applications requiring high concentrated heat. This study investigates the influence of three physical mixing techniques—mortar-pestle, magnetic stirring, and ball milling—on the morphology, reactivity, and thermal behaviour of Al-NiO thermites under different heating rates (20, 35, 50 oC/min). Advanced characterization techniques, including SEM/EDS, particle size distribution (PSD) analysis, zeta potential (ZP), DSC/TGA, and electrothermal ignition tests, were employed. The results reveal that ball milling significantly reduces particle size to the nanoscale and enhances ignition properties, despite limited improvements in homogeneity due to agglomeration tendencies. Thermal analyses showed that, while all techniques produced good thermal properties, the ball-milled thermite demonstrated activation energy and ignition characteristics consistent with nanoscale systems. Faster heating rates revealed distinct morphological outcomes and reaction pathways among mixing techniques. Importantly, this study demonstrates that cost-effective mixing methods can still yield thermites with promising thermal and ignition properties, suggesting their potential for scalable industrial applications. These findings contribute to optimizing Al-NiO thermites for advanced energetic systems in both civilian and military domains.</jats:p>