Dr. Pantoya’s team focused on a common challenge: aluminum naturally forms a shell of alumina (Al₂O₃) when exposed to air. This shell prevents the aluminum from reacting quickly, which is useful for storage and safety, but limits the rate of energy released during combustion. The researchers explored ways to modify this shell without compromising the aluminum core inside.

By exposing alumina-coated aluminum microparticles to water and gentle heating, in a process known as hydration, they could convert the shell into a more reactive material called bayerite (Al(OH)₃). Bayerite allows oxygen to reach the aluminum core more easily, enabling a faster, more efficient burn.

Through careful experimentation, Dr. Pantoya’s team optimized the hydration process, ensuring that the transformation occurred without damaging the aluminum core. By maintaining a controlled temperature and hydration time, they successfully preserved 96% of the aluminum core while converting the shell. This balance is critical – too much hydration could degrade the aluminum, while too little wouldn’t provide enough of a performance boost.

Combustion tests revealed that the bayerite-coated aluminum particles burned 18% faster than their alumina-shelled counterparts. Under high-pressure conditions, where combustion is even more demanding, the improvements were even more pronounced.

The bayerite shell also released oxidizing gases close to the aluminum core, ensuring that oxygen reached the reaction site exactly when needed. This efficient combustion process led to greater power output and reduced waste, making the modified aluminum particles ideal for high-energy applications.

Dr. Pantoya’s research doesn’t just improve the speed of combustion – it enhances its control and efficiency. Faster-burning particles mean quicker energy release, which is vital in propulsion systems where even tiny delays can impact performance. More efficient combustion also means less wasted material, making these advances more sustainable.

By tweaking the chemistry of aluminum’s protective shell, Dr. Pantoya and her team have paved the way for more powerful and reliable fuels.