Reactive Forging − Pressure Assisted Thermal Explosion Mode of SHS for Processing Dense In Situ Composites and Structural Parts: A Review

Abstract

Over the last decades, there has been a decisive shift from basic science to applied research that brought about the development of a number of unconventional combustion processes that allow for simultaneous synthesis and consolidation of otherwise difficult-to-process high temperature materials. External pressure application during thermal explosion (TE) mode of self-propagating high-temperature synthesis (SHS) can produce dense products provided the combination temperature and pressure are sufficient for consolidation. In the developed TE-based reactive forging (RF) method, a self-sustained reaction is ignited by rapid heat transfer from press die and rams, and a moderate consolidation pressure is applied when the combustion product still contains a sufficient amount of liquid or very soft phase. Plastic flow of the product results in filling the shape of the die thus producing a near-net-shape part. Reactive forging (RF) is especially efficient in combination with the developed short distance infiltration (SDI) approach based on the presence of a low melting phase component (e.g., Al, Mg, Ti-Ni eutectics) in the non-dense reactant blend that is squeezed into the pores under the applied pressure thereby increasing the interparticle contact area and enhancing exothermic heat release rate. Compared to traditional reactive melt infiltration, SDI has the advantage of the considerably shorter infiltration distances (μm vs. mm-cm). Close temperature monitoring during RF and RF/SDI processing provides a deeper insight into the SHS reaction mechanisms. The "heat sink" action of the pressure die after TE results in rapid cooling of the consolidated products and correspondingly fine microstructures and high mechanical properties. Examples of successful application of the RF/SDI processing of homogeneous and functionally graded in situ composites based on binary (Al 2 O 3 , TiB 2 , TiC, TiN) and ternary (MgAl 2 O 4 , Ti 3 SiC 2 , Ti 3 AlC 2 ) ceramics, as well as intermetallic-ceramic and metal-ceramic interpenetrating phase composites are described. Nanostructuring of reactant blends results in lower SHS ignition temperatures, and thus can be utilized for two-stage ignition of multi-component composite materials and structures with tunable ignition delay. Pressure assisted SHS is a "green," cost-effective, and thus perspective manufacturing route of nearnet-shape structural parts. Examples of successful application of RF and RF-SDI approach to fabrication of ceramic matrix-diamond grinding wheels, light armor tiles and high melting temperature nozzles are presented.

Fabrication of a Porous Fe–Al Intermetallic Alloy with Ultrahigh Open Porosity

“…[6,7,10] Thus, they have been recently considered as promising filtration and separation candidates operating in harsh environments. [11][12][13][14][15][16] Different kinds of methods have been developed to prepare porous Fe-Al intermetallic materials, including reactive synthesis method, [4,8,[17][18][19][20] thermal explosion (TE) method, [21][22][23][24] and space holder method. [25][26][27] Reactive synthesis method has been widely used to produce porous Fe-Al intermetallic materials.…”

“…Different kinds of methods have been developed to prepare porous Fe–Al intermetallic materials, including reactive synthesis method, [ 4,8,17–20 ] thermal explosion (TE) method, [ 21–24 ] and space holder method. [ 25–27 ] Reactive synthesis method has been widely used to produce porous Fe–Al intermetallic materials.…”

Fabrication, Microstructure and Properties of Nickel/Epoxy Resin Functionally Graded Materials With Magnetic-Field-Driving Method

“…Functionally graded materials (FGMs) are inhomogeneous composites with continuous changes in spatial dimension from the compositions, microstructures and properties (Song et al, 2008;Zhang et al, 2013;Wang et al, 2018). FGMs are usually designed for the heterogeneous properties (mechanical properties (Gotman and Gutmanas, 2018), thermal properties (Anh et al, 2016), optical properties (Marteau and Bouvier, 2016), magnetic properties (Kang et al, 2017), etc. that generally cannot be fabricated by using traditional preparation process.…”

Molten Salt Electrochemical Synthesis of Ternary Carbide Ti3AlC2 from Titanium‐Rich Slag

“…In addition, porous Ti 3 AlC 2 wicks exhibit good thermal stability and reliability in the evaporator of a loop heat pipe . Since the first synthesis of Ti 3 AlC 2 through the sintering of Ti–TiAl–Al 4 C 3 –C powders mixture by Pietzka and Schuster, nowadays, various synthesis methods including hot pressing (HP), pulse discharge sintering (PDS), self‐propagating high‐temperature synthesis (SHS), etc . are being utilized to prepare Ti 3 AlC 2 .…”

“…[11] Since the first synthesis of Ti 3 AlC 2 through the sintering of Ti-TiAl-Al 4 C 3 -C powders mixture by Pietzka and Schuster, [12] nowadays, various synthesis methods including hot pressing (HP), pulse discharge sintering (PDS), selfpropagating high-temperature synthesis (SHS), etc. [3,[13][14][15][16][17] are being utilized to prepare Ti 3 AlC 2 . Among them, the SHS method attracts attention due to its highefficient properties.…”