General Mechanism Review of Aluminum‐Based Thermite Reaction

The thermite reaction exhibits significant application potential in solid propellants, high‐temperature welding, and nanoenergetic materials due to its high energy density, self‐sustaining combustion capability in oxygen‐deficient environments, and tunable composition. This review systematically introduces alumina layer dynamics, diffusion–oxidation mechanism, and melt‐dispersion mechanism, alongside reaction pathway distinctions between Al/oxide and Al/fluoride systems. It further highlights the regulatory roles of graphene and its derivatives (e.g., GO and GF) in enhancing combustion performance and reducing sensitivity. Additionally, reactivity differences between micron‐ and nanosized aluminum particles are analyzed, emphasizing size‐dependent ignition and combustion dynamics. By elucidating competitive and synergistic interactions among multiscale reaction mechanisms, energy release patterns in aluminum‐based thermite systems are clarified. Future research should integrate computational simulations with experimental techniques to optimize interfacial reaction pathways and mitigate diffusion barriers. Such efforts will advance the design of aluminum‐based high‐energy materials with enhanced combustion efficiency and stability under extreme conditions, addressing challenges in aerospace, defense, and energy applications.