The energetics of cast calcium sulfate dihydrate-aluminium thermites was explored and its use as a potential metal-cutting tool was investigated. Thermite is a pyrotechnic composition that undergoes a highly exothermic reaction that burns relatively slowly. It is often used in cutting, welding and incendiary devices. Consolidation of thermite by casting was chosen to enable control of the burning front. The base case thermite comprised 60 wt-% calcium sulfate dihydrate oxidiser and 40 wt-% aluminium fuel. Addition of additives were considered for their effect on the cast thermite’s setting time, density, surface temperature, reaction products and burn rate. EKVI and FactSage thermodynamic simulations were used to determine optimum compositions for the various systems. The thermite powder compositions were sieved before mixing with water and casting in a mould. The casts were allowed to set for 3 days to form calcium sulfate dihydrate-aluminium compositions. The copper sulfate pentahydrate additive was found to significantly decrease the setting time of the casts. The heat of hydration of the base case was 59 ± 8 J g−1 . The compressive strength reached 2.9 ± 0.2 MPa, the open air burn rate was 12.0 ± 1.6 mm s −1 and a maximum surface temperature of 1370 ± 64 °C was recorded using a pyrometer. Bomb calorimetry indicated an energy output of 7.96 ± 1.07 MJ kg−1 , slightly lower than predicted by the EKVI simulation. The density of the castings was varied by either adding hollow sodium borosilicate glass spheres or by adding excess water. The glass spheres resulted in a burn rate that decreased nonlinearly with decreasing cast density. The excess water made no changes to the burning, except for increasing the burn rate of the copper sulfate pentahydrate-based thermite. Calcium sulfate in the casts was also dehydrated by thermal treatments at 155 °C and 200 °C. This resulted in significant increases in the burn rate due to the porosity created by the evaporation of the hydration waters. Castings that were thermally treated in an oven at 155 °C were successful in puncturing part of an aluminium block in confined burn tests. A hole with a diameter of ~13.6 mm and depth of ~7 mm was produced. It is recommended that the composition with copper sulfate pentahydrate be used as a binder in further tests. / Dissertation (MEng)--University of Pretoria, 2018. / Chemical Engineering / MEng / Unrestricted