The combustion performance of metal particles for explosives, propellants, pyrotechnics, and bio-agent defeat can be optimized by controlling the chemistry, size, and coatings of the particles. Many pure and composite metal fuels used in these applications have been observed to microexplode during combustion. This causes particles to fragment, revealing fresh surfaces, which may enhance burn rates and efficiencies. Despite these potential benefits, few have attempted to control the bubbling and the microexplosion of metal powders as they combust in molten states. Here, we choose Al:Zr composite powders as a representative system to study bubbling and microexplosions and to identify active mechanisms. Using synchrotron x-rays and phase contrast imaging, we observe molten metal particles of various sizes as they burn in air at temperatures ranging from 2700 to 3500 K. We characterize bubble nucleation and growth in the interior of the particles during the combustion process, and we identify heterogeneous nucleation, slow growth and coalescence of bubbles, as well as rapid bubble growth leading to microexplosions. Bubble growth rates and Laplace pressures are calculated, and we find that during slow expansion growth rates are similar to classical predictions of bubble growth in superheated liquids. For rapid expansions we find that a critical growth rate of similar to 0.5m s(-1), independent of the initial particle size, is necessary to enable microexplosions. We calculate the rate of gas generation that is needed to enable this growth and we conclude that nitrogen is the gas most likely driving rapid bubble growth and fragmentation. These results provide the first in situ observations of the mechanisms that control bubbling and microexplosions during the combustion of metal particles. (C) 2018 The Combustion Institute. Published by Elsevier Inc. All rights reserved.