Reactive foils and their uses are provided as localized heat sources useful,
for example, in ignition, joining and propulsion. An improved reactive foil is
preferably a freestanding multilayered foil structure made up of alternating layers
selected from materials that will react with one another in an exothermic and self-propagating
reaction. Upon reacting, this foil supplies highly localized heat energy that may
be applied, for example, to joining layers, or directly to bulk materials that
are to be joined. This foil heat-source allows rapid bonding to occur at room temperature
in virtually any environment (e.g., air, vacuum, water, etc.). If a joining material
is used, the foil reaction will supply enough heat to melt or soften the joining
material, which upon cooling will form a strong bond, joining two or more bulk
materials. If no joining material is used, the foil reaction supplies heat directly
to at least two bulk materials, melting or softening a portion of each bulk, which
upon cooling, form a strong bond. Additionally, the foil may be designed with openings
that allow extrusion of the joining (or bulk) material through the foil to enhance bonding.