Visual and infrared signature powder and preparation methods thereof

1. A method of preparing a visual and infrared signature composition (VIS-IR powder) comprising:

1a. mixing a first metal composition with a binder composition with a first solvent to provide a first mixture, wherein:

the first metal composition comprises aluminum and tin,

the binder composition comprises one or more binder components selected from the group consisting of dispersants, organic binders, wetting agents, lubricants, silicate binders, and metasilicate binders, and optionally

the binder composition is dispersed in the first solvent;

1b. separating solid from liquid from the first mixture and drying the solid to provide a first solid;

1c. combining the first solid with a second metal composition to provide a second mixture, wherein the second metal composition comprises particles of one or more metals selected from the group consisting of iron, nickel, cobalt, titanium, and zirconium;

1d. heating the second mixture to provide a first inter-metallic composition;

1e. grinding the first inter-metallic composition to provide a ground first inter-metallic composition;

1f. adding the ground first inter-metallic composition to a leaching solution comprising one or more strong bases and providing a leached mixture;

1g. separating solid from liquid from the leached mixture to provide a second solid;

1h. rinsing the second solid with one or more rinsing solutions; and

1i. drying the second solid to provide the VIS-IR powder.

2. The method according to claim 1 , wherein the silicate binders are selected from the group consisting of sodium silicate, potassium silicate, lithium silicate, and alkyl ammonium silicates; and metasilicate binders are selected from the group consisting of the sodium metasilicate, potassium metasilicate, lithium metasilicate, and alkyl ammonium metasilicates.

3. The method according to claim 1 , wherein the silicate binders are selected from the group consisting of sodium silicate, potassium silicate, and lithium silicate; metasilicate binders are selected from the group consisting of the sodium metasilicate, potassium metasilicate, and lithium metasilicate.

4. The method according to claim 3 , wherein the first solvent is an aqueous-based solvent that has a neutral pH.

5. The method according to claim 3 , wherein the first solvent is an aqueous-based solvent that comprises one or more corrosion inhibitors.

6. The method according to claim 5 , wherein the corrosion inhibitors are selected from the group consisting of silicates, alkyl phosphates, inorganic phosphates, phosphonates, and alkyl ammonium halide salts.

7. The method according to claim 1 , wherein the silicate binders are selected from the group consisting of lithium silicates and alkyl ammonium silicates; metasilicate binders are selected from the group consisting of lithium metasilicate and alkyl ammonium metasilicates.

8. The method according to claim 7 , wherein the first solvent is an organic solvent selected from the group consisting of toluene, hexane, cyclohexane, MEK, MBA, alcohols, esters, dioxane, tetrahydrofuran, acetone, and any mixtures thereof.

9. A method of preparing a visual and infrared signature composition (VIS-IR powder) comprising:

2a. mixing the dry particles of a first metal composition with a binder composition comprising one or more metasilicate binders selected from the group consisting of sodium metasilicate, lithium metasilicate, and potassium metasilicate to provide a first mixture, wherein the first metal composition comprises aluminum and tin;

1c′. combining the first mixture with a second metal composition to provide a second mixture, wherein the second metal composition comprises particles of one or more metals selected from the group consisting of iron, nickel, cobalt, titanium, and zirconium;

1d. heating the second mixture to provide a first inter-metallic composition;

1e. grinding the first inter-metallic composition to provide a ground first inter-metallic composition;

1f. adding the ground first inter-metallic composition to a leaching solution comprising one or more strong bases and providing a leached mixture;

1g. separating solid from liquid from the leached mixture to provide a second solid;

1h. rinsing the second solid with one or more rinsing solutions; and

1i. drying the second solid to provide the VIS-IR powder.

10. The method according to claim 1 , wherein the one or more strong bases for the leaching of step 1f are selected from the group consisting of NaOH and KOH.

11. The method according to claim 1 , wherein the intermetallic composition is formed by heating the second mixture at a temperature that is higher than the melting point of the aluminum-tin eutectic therein.

12. The method according to claim 1 , wherein the leaching solution comprises a base that may remove aluminum from the intermetallic composition.

13. The method according to claim 1 , wherein the rinsing solutions are selected from the group consisting of water, aqueous solution comprising one or more acids, and organic solvents.

14. The method according to claim 9 , wherein the one or more strong bases for the leaching of step 1f are selected from the group consisting of NaOH and KOH.

15. The method according to claim 9 , wherein the intermetallic composition is formed by heating the second mixture at a temperature that is higher than the melting point of the aluminum-tin eutectic therein.

16. The method according to claim 9 , wherein the leaching solution comprises a base that may remove aluminum from the intermetallic composition.

17. The method according to claim 9 , wherein the rinsing solutions are selected from the group consisting of water, aqueous solution comprising one or more acids, and organic solvents.