A Critical Review on the Properties of Intermetallic Compounds and Their Application in the Modern Manufacturing

Abstract

Advancement in modern manufacturing processes is allowing researchers to develop new alloy configurations for different applications to reduce weight and increase efficiency. Many alloy combinations are produced that randomly generate different phases of intermetallic compounds (IMCs) in the structure during manufacturing which show unique mechanical and chemical properties. But, the fundamental knowledge of different IMCs is scattered across the material research domain. Thus, in this review, the crystal structures of IMCs are thoroughly discussed which are having structural and functional applications. Furthermore, the issues associated with the dissimilar Fe‐Al, Fe‐Ni, and Ni‐Al systems via modern manufacturing processes such as arc additive manufacturing have been discussed. Moreover, detailed knowledge of ferro‐nickel, nickel‐aluminides, and ferro‐aluminides formed at the interface during the dissimilar deposition in modern manufacturing is provided. Currently, a few transition metal IMCs and some Heusler alloys, are the most promising and are used in applications. The addition of a third alloying element provides the broadening effect on the phase domain of a specific IMC. Furthermore, it has been observed that modern manufacturing processes such as additive manufacturing and others are new and advanced manufacturing technologies used for dissimilar metal deposition, which can control the IMCs in a more favorable direction.

Heat‐Resistant Intermetallic Compounds and Ceramic Dispersion Alloys for Additive Manufacturing: A Review

“…[ 21 ] The mechanical properties of ICs are strongly influenced by the type of bonding, which depends on the valency and electronegativity differences between elements. [ 2–4 ]…”

“…[21] The mechanical properties of ICs are strongly influenced by the type of bonding, which depends on the valency and electronegativity differences between elements. [2][3][4] Due to the additional ionic bonding and formation of ordered structures, aluminides such as β-NiAl, γ-Ni 3 Al, γ-TiAl, α 2 -Ti 3 Al, B2-FeAl, and D0 3 -Fe 3 Al demonstrate high melting point and excellent high-temperature microstructure stability and oxidation resistance. [3,22,23] However, the different atomic species form ordered arrangements, leading to superlattice structures with low symmetry and high resistance to deformation by dislocation motion, which causes low-temperature embrittlement whereby the failure strain and fracture toughness are low below the DBTT.…”

“…[2][3][4] Due to the additional ionic bonding and formation of ordered structures, aluminides such as β-NiAl, γ-Ni 3 Al, γ-TiAl, α 2 -Ti 3 Al, B2-FeAl, and D0 3 -Fe 3 Al demonstrate high melting point and excellent high-temperature microstructure stability and oxidation resistance. [3,22,23] However, the different atomic species form ordered arrangements, leading to superlattice structures with low symmetry and high resistance to deformation by dislocation motion, which causes low-temperature embrittlement whereby the failure strain and fracture toughness are low below the DBTT. [24] Therefore, manufacturing and post-processing of these materials present challenges for industry due to high cracking and fracture potential.…”

“…[1] Furthermore, atomic bonding consists of not only metallic bonds, but also ionic or covalent bonds, increasing not only brittleness but also high-temperature strength retention. [2][3][4] ICs may be present as precipitates within a traditional alloy. [5] Moreover, ICs may be reinforced with non-IC components, forming composites.…”

Properties of Al2O3/Ti/Ni Composite Obtained by Slip Casting with Different Metal Phase Content

“…In the literature, few ceramic-metal composites are widely described in terms of welding and rolling of Ti-15Mo/TiB [ 10 , 11 ], microstructure and properties of TiBw/Ti6Al4V [ 12 , 13 ], and manufacturing and characterization of Ti-TiB composites [ 14 , 15 , 16 , 17 ]. It is worth mentioning that a significant modification of this group of composites may be the replacement of metallic phases with intermetallic phases, which in their properties constitute a kind of bridge between metallic and ceramic materials [ 18 , 19 ]. The combination of ductility, high strength, abrasion resistance and hardness makes the intermetallic compounds an excellent modification of the classic, metallic reinforcement of ceramic composites [ 20 ].…”