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Volume 07 - Powder Metal Technologies and Applications Part 9 ppsx

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Huo, Determination of Threshold Pressure for Infiltration of Liquid Aluminum into Short Alumina Fiber Preform, Trans.. Huo, Determination of Threshold Pressure for Infiltration of Liqui

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Fig 4 Schematic drawing of microstructure of tungsten sintered at different temperatures before being

immersed into molten copper (a) 1100 °C (2010 °F) (b) 1350 °C (2460 °F) (c) 1600 °C (2910 °F) (d) 2800

°C (5070 °F) 500× Source: Ref 16

Infiltrated bodies that have a continuous skeleton phase above approximately 65 vol% can be shaped only by machining, while those having a smaller proportion of refractory metal dispersed as loose grains in the ductile metal matrix are plastically deformable at elevated temperatures (Ref 8) Soldering, brazing, or plating of the infiltrated product is aided by generally smooth surface films or high contents of infiltrant metal

The preceding binary systems illustrate combinations of two metals of widely differing melting temperatures that can be advantageously produced to near-net shape and full density by infiltration Nickel also can be infiltrated into tungsten, but equilibrium at liquid-phase temperature causes severe attack of the refractory metal and requires careful process control to prevent incomplete penetration due to diffusion solidification Coarse tungsten powder helps to produce compacts with larger capillary channels for better penetration High heating rates, especially after about 90% of the absolute melting temperature of nickel is reached, improve infiltration conditions

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If nickel is alloyed with copper, the solubility of tungsten in the liquid phase decreases as the copper percentage is increased Infiltration is more practical (Ref 8) for heavy alloy systems because tungsten powder and process control requirements are less stringent If nickel is alloyed with iron, however, the solid-liquid phase interaction is similar to the binary tungsten-nickel system, and infiltration again is more difficult

The same principle applies to the more complex refractory metal systems with nickel-chromium and cobalt-chromium alloys Nevertheless, skeleton bodies of tungsten and molybdenum, as well as bodies of binary 85W-15Cr and 75W-25Cr alloys, can be successfully infiltrated with superalloys of the Nichrome-V, Hastelloy-C, Stellite, and Vitallium compositions into shapes simulating mechanical and engine test specimens (Ref 17)

Several other refractory metal-based composite structures can be readily produced by infiltration These include the density tungsten-lead system to produce materials suitable for shielding against radiation and the chromium-copper system to produce compositions for welding electrodes (Ref 8) To retain the low liquid-solid contact angles in these systems, a strong reducing atmosphere is necessary to prevent oxide films on the molten lead or on the solid chromium A free metallic surface requires sintering of the skeleton above 1250 °C (2280 °F) to reduce any oxide film on the solid chromium

high-Carbide-Based Systems. Liquid-phase sintering of tungsten carbide/cobalt or titanium carbide/nickel systems capitalizes on the eutectics of the two phases A limited solubility of the carbide in the matrix metal facilitates bonding; carbon and metal diffusion through the liquid are less important in densification than reactions at the carbide-metal phase boundaries It is unknown whether the carbide particles in these systems form a rigid skeleton, but the interfacial tension between crystals of the carbide and the liquid metal appears to be anisotropic (Ref 18)

During cooling from the sintering temperature, some or most of the carbon and metal dissolved in the liquid precipitates

on grains that remained solid during the process This mechanism can be altered somewhat if the rigid skeleton is formed first and the liquid phase subsequently infiltrates into the pore system By first saturating the matrix metal with carbon and skeleton metal, the liquid phase dissolves less skeleton materials, and shape distortion is diminished Carbide coalescence and grain growth also are decreased

The earliest attempts to produce cemented carbides were made by infiltrating carbide skeletons with unalloyed binder metals (Ref 19) Later, binder metal prealloyed with elements of the skeleton to inhibit contact face erosion was used in a broad investigation of infiltrating single and double carbides with many cobalt and nickel alloys (Ref 20) Table 2 lists some of the alloys used The large number of feasible combinations includes several noteworthy successes, especially for titanium carbide-based stems with Nichrome and Vitallium infiltrants A feasibility study (Ref 17) produced similar results for the same infiltration systems and laid the foundation for an extensive development program to utilize these materials for heat-resistant applications

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Table 2 Carbide infiltration test matrix and evaluation

%

Infiltrant composition,

%

Type

°C °F

Time, min

Very tough 1b

11.05- 14.6

29.3-60Co-40WC

Contact, opposing sides(d)

1350 2460 5

85-86 No erosion,

heavy residue

Porous in core, graphite precipitates, fairly uniform grain size

6.65- 21.3 95Co-5WC

37.1-Contact, opposing sides(d)

1460 2660 15

85.6-87 Contact face

erosion

Uniform phase distribution, some porosity

3b

72.7Co- 10TiC

3.01- 19.3

33.2-80Ni-20Cr

Contact, opposing sides(d)

1450 2640 15 24.6Ni,

6.1Cr, bal TiC

4b

72.7Co- 10TiC

17.3Cr-Contact, one side(d)

1400 2550 5

88+ Less contact

face residue than in 4a

Higher matrix concentration near contact face, porosity increasing toward far end

Tough where dense, brittle where porous

3.38- 11.4

25.7-80Ni-20Cr Capillary

dip in molten infiltrant

1550 2820 3 22.5Ni,

5.7Cr, 2.1Mo 2 C, bal TiC

84.5-85 Alloy skin

becoming heavier toward bottom, forming excess on bottom end

Uniform phase distribution, generally dense

3.46- 11.6

24.8-

72.7Co-Contact, one side(d)

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10TiC

17.3Cr-contact face residue

72.7Ni- 10TiC

17.3Cr-Capillary dip in molten infiltrant

1550 2820 3 85 Similar to 4d Similar to 4d Tough 5d

90TiC-10Mo 2 C(e)

4.14

3.54- 14.6

26.0-80Ni-20Cr Contact,

opposing sides(d)

1400 2550 15 22.9Ni,

5.5Cr, 7.1Mo 2 C, bal TiC

85-86 Slight

contact face erosion, small residue, slightly porous

Porous in core, less uniform phase distribution than in 4d

Less tough than 4 and 5

6

70TiC-30Mo 2 C(e)

4.75

4.09-22.9-9.9 80Ni-20Cr Contact,

opposing sides(d)

1400 2550 15 22.6Ni,

5.6Cr, 21.4Mo 2 C, bal TiC

86-87 Similar to 6,

but more porous

More porous in core, less uniform phase distribution than in 6

More brittle than 6

7

50TiC-50Mo 2 C(e)

5.58

4.69-21.3-8.3 80Ni-20Cr Contact,

opposing sides(d)

1400 2550 15 22.3Ni,

5.7Cr, 35.8Mo 2 C bal TiC

86-87 Similar to 7,

but more porous

Very porous, nonuniform phase distribution

More brittle than 7

8

Source: Ref 19

(a) All skeletons were presintered at 950 °C (1740 °F) and high sintered at 1500 °C (2730 °F) for 2 h in a carbon tube resistor furnace under hydrogen,

except No 1 to 3, which were high sintered in vacua in a carbon susceptor induction furnace

(c) A qualitative assessment of resistance against fragmentation by hammer blows

(d) Infiltrant mass was 40 to 45% of mass of infiltrated product

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The structure of infiltrated carbides reflects infiltration mechanics on a macroscale In zones penetrated by the infiltrant, fully dense regions and slight expansion of the skeleton due to carbide grain separation are observed Substantial porosity and some shrinkage occur in areas inadequately penetrated by the liquid alloy, such as the side opposite the contact face

in unidirectional infiltration, or in the center for infiltration from opposite sides Subsequent heat treatment is ineffective

in eliminating porosity Erosion at the contact faces is greatly diminished by infiltrating skeletons composed of base multicarbides, so that saturating the infiltrant with skeleton elements by prealloys frequently is not required

tungsten-The microstructure reflects the crystallographic characteristics of the carbide, and fully infiltrated regions do not differ in grain size and morphology from material whose liquid phase was sintered in situ Rectangular and triangular grains are retained in infiltrated tungsten carbide, whereas for infiltrated titanium carbide, the cubic lattice is reflected by distinctly rounded grains Grains of solid-solution carbides of tungsten and titanium or titanium and molybdenum are slightly rounded at the corners Graphite precipitates accompany porosity in poorly infiltrated regions for tungsten carbide and titanium carbide skeletons, especially if starting powders contain more than a trace of free carbon

Ferrous-Base Systems. The thermodynamic affinity between solid iron and liquid copper offers the potential for virtually pore-free P/M products by infiltration Moreover, the excellent wetting characteristics that exist in the brazing of steel can also be utilized for joining disparate bodies during infiltration A powder compact and a casting or forging, or halves of complex or offset configurations, can be joined Figure 5 (Ref 10) illustrates this self-brazing capacity without strength degradation Finally, the generally smooth cupric film surrounding the infiltrated body serves as a base for surface coating or plating

Fig 5 Infiltration-brazed butted iron-copper bars Green bars were clamped together end-to-end, and one free

end surface was contacted with molten infiltrant Rupture of composite bar occurred away from the joint, evidence of the high strength of the brazed bond (a) Butt joined bars after infiltration (b) Machined tensile bar (c) Tested tensile bar

The ability of the infiltration process to combine major proportions of normally unalloyable industrial premier metals (iron and copper) was recognized as early as World War I (Ref 21, 22), but it was only in the late 1940s, through refinements in technique, that sound products could be made (Ref 10, 23, 24, 25) These products, in turn, have culminated in the present advanced state of the art While copper content must be higher than for most commercially sintered iron-copper alloys because of the need to maintain an interconnected pore system for complete infiltration, good mechanical properties can be realized

This is apparent from the tensile strength-elongation data given in Fig 6 for commercial iron powder with and without graphite additions (Ref 24) Strength is enhanced because the infiltrated structure, with a minimal amount of isolated pores, is virtually free of internal notches The iron-copper system permits a precipitation-strengthening mechanism If carbon is diffused into the iron to produce a hypoeutectoid structure of the skeleton, hardening by martensite transformation is possible Where other metals are alloyed with the copper, solid solution strengthening of the matrix can

be achieved

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Fig 6 Mechanical property ranges of copper-infiltrated iron and hypoeutectoid steel compacts before and after

heat treatment

In the binary iron-copper system, about 3.8 to 4% Fe is dissolved by the liquid copper under equilibrium conditions at an infiltration temperature of 25 to 50 °C (45 to 90 °F) above the peritectic temperature of 1090 °C (2000 °F) at the copper side of the phase diagram, while the -iron dissolves about 8 to 8.5% of the copper At 900 °C (1650 °F), the solubility

of -iron in copper is about 1.5%; it diminishes to less than 0.04% at room temperature, at which point the solubility of copper in iron is equally low

These thermodynamic relations form the basis for precipitation hardening However, macrodispersion of the two phases

in the infiltrated alloys causes concentration of precipitates in thin zones at the phase boundaries, as shown in Fig 7 (Ref 26) Consequently, conventional hardness tests are not precise enough to show a noticeable increase in macrohardness after a precipitation treatment, such as quenching from 900 °C (1650 °F) followed by prolonged tempering at 600 °C (1110 °F) The precipitation mechanism produces increases in strength, elongation, and impact resistance (Ref 8) and also can be traced through changes in the electrical conductivity (Ref 25)

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Fig 7 Microstructure of 25Cu-Fe compact sintered at 1100 °C (2010 °F) for 30 min Large, rounded, dark areas

are -iron, separated by a diffusion layer from the light copper phase containing the fine, dark, iron-rich precipitate 1000× Source: Ref 26

If carbon is diffused into the iron skeleton with copper infiltrated afterward, two processes compete with one another during cooling During quenching, normal martensitic transformation occurs inside the skeleton structure At the same time, however, precipitation of the dissolved iron in the copper and copper in iron, respectively, is suppressed in the phase boundary zones During reheating, martensite decomposition causes a decrease in hardness of the steel skeleton structure, with simultaneous increases in hardness and strength of the boundary zones

Table 3 shows the effect of such a heat treatment on the mechanical properties of a copper-infiltrated 0.3% carbon steel Water quenching produces an appreciable increase in hardness and brittleness With increasing reheating temperatures, however, the material becomes softer and tougher, without loss in strength (Ref 8)

Table 3 Effect of heat treatment on the mechanical properties of 0.3% carbon steel infiltrated with 11 vol% Cu

Ultimate

tensile strength

Impact resistance (b)

Reheated to 900 °C (1650 °F) and water quenched 437 790 114.6 5.2 11.76 8.68

Reheated for 2 h at 400 °C (750 °F) 360 14.71 10.85

Reheated for 2 h at 500 °C (930 °F) 302 771 111.8 7.6 23.14 17.07

Reheated for 2 h at 600 °C (1110 °F) 255 750 108.8 13.5 62.75 46.30

(a) Hametag iron powder pressed to 88% of theoretical density, sintered at 1220 °C (2230 °F) for 1 h in

hydrogen, and infiltrated with electrolytic copper at 1100 °C (2010 °F) for 30 min

(b) Unnotched test bar of 1 cm2 cross section

When a copper alloy is used as an infiltrant, other benefits can accrue When precipitates form in the matrix, such as copper alloys with beryllium, chromium, or silicon, the resulting strength increase during heat treating of the infiltrated body reinforces iron-copper precipitation zones at the boundaries The strengthening effect of precipitates is independent

of heat treatment and augments strength increases obtained with unalloyed copper infiltrant in solid-solution alloys However, some solid-solution alloy infiltrants minimize erosion at the point of initial contact with the iron skeleton, because these alloys melt slowly over a range of temperatures Brass containing 20% Zn exhibits this phenomenon

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A copper alloy with manganese in amounts up to 5%, especially if it also contains sufficient iron to inhibit a severe attack

of the skeleton contact faces, has a different beneficial effect The manganese oxidizes preferentially in the commercial atmospheres where infiltration takes place A nonadhering porous crust results that can be removed during finishing more easily than the tenacious residue formed by a binary copper-iron infiltrant (Ref 27, 28)

Many ferrous metal-base infiltration systems have been explored experimentally Kieffer and Benesovsky (Ref 8) have investigated the iron-gold, iron-bismuth, iron-cadmium, iron-lead, iron-antimony, and iron-tin systems for bearings, and the iron-cobalt-silicon, iron-copper-silicon, and iron-manganese-silicon systems for magnetic or structural parts Alloys of the iron-zinc system have also been produced by infiltration, but treatment in a pressure vessel is required to overcome the high vapor pressure of the zinc (Ref 29)

Austenitic stainless steel skeletons infiltrated with silver possess excellent corrosion resistance, thus making them suitable for food processing applications Ferritic stainless steel and high-manganese steel compacts with varying carbon contents also display improved corrosion resistance when infiltrated with cupric alloys These alloys also exhibit extraordinary hardness and wear resistance, coupled with a considerable toughness Table 4 lists mechanical and technological properties of several ferrous-base infiltrated materials

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Table 4 Properties of some ferrous metal-based infiltrated alloys

tensile strength

Impact resistance(a)

Skeleton

composition,

%

Infiltrant composition,

93.2Fe-6Mn-0.8C 100Cu 13 7.90 7.87 740 Naturally hard, wear resistant

87.2Fe-12Mn-0.8C 100Cu 9 7.89 7.69 310 562 81.5 6 Wear resistant, work hardening

93.5Fe-3Cr-3Mn-0.5C 100Cu 14 7.96 7.93 502 957 138.8 4

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Nonferrous-Based Systems. The major nonferrous metals with higher melting points are thermodynamically compatible with many low-melting metals in the liquid state Consequently, skeleton bodies of cobalt and nickel can be readily infiltrated with gold, as well as with many of the low-melting heavy metals, such as bismuth, lead, or antimony (Ref 8) Copper can also be infiltrated into cobalt and nickel skeletons; however, because of the formation of solid solution in all proportions, infiltration into nickel powder compacts requires a narrow particle size range, wide capillaries within a pore volume not exceeding about 35%, short infiltration time, and a vacuum to assist the capillary forces Mercury wets nickel well without forming an amalgam and is easily impregnated into skeleton bodies, provided the pore structure prevents exudation of the heavy liquid metal (Ref 30)

Copper is another skeleton metal with pores that can be readily filled with liquid low-melting-point metals, such as lead (Ref 31, 32) or bismuth (Ref 33) Vacuum impregnation is suitable for incorporating lead-base alloys, such as those containing 15% Sb and 5 to 10% Sn, into spongy structures of nickel-copper or nickel-iron supported by steel backing (Ref 34)

Combinations of aluminum or aluminum alloys with low-melting metals such as bismuth, lead, thallium, or thallium-lead

by means of infiltration in hydrogen or a vacuum have been proposed (Ref 33, 35) However, strict control of powder characteristics, especially particle shape and surface condition, to maximize wetting appears to put infiltration at a disadvantage over in situ liquid-phase sintering To overcome this problem, zinc or cadmium can be added to the aluminum of the skeleton, followed by cleaning and activating the free surface of the pores by evaporation of the lower boiling metal before proceeding with the impregnation of a metal such as lead (Ref 36)

References cited in this section

8 R Kieffer and F Benesovsky, The Production and Properties of Novel Sintered Alloys (Infiltrated Alloys),

Berg- und Hüttenmännische Monatshefte, Vol 94 (No 8/9), 1949, p 284-294

10 F.V Lend, Powder Metallurgy, Metal Powder Industries Federation, 1980, p 313-319

15 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 196

16 K Schröter, Border Regions of Metallography, Z Metallkd., Vol 23 (No 7), 1931, p 197-201

17 J.M Krol and C.G Goetzel, "Refractory Metal Reinforced Super Alloys," USAF Technical Report 5892, ATI No 57154, May 1949

18 F.V Lend, Powder Metallurgy, Metal Powder Industries Federation, 1980, p 383-400

19 R Kieffer and F Kölbl, Production of Hard Metals by Infiltration, Berg Hüttenmämann Monatsh., Vol 95

22 C.L Gebauer, Process of Producing Metal Bodies, U.S Patent 1,342,801, 1920; C.L Gebauer, Production

of a Composite Metallic Article, U.S Patent 1,395,269, 1921

23 F.P Peters, Cemented Steels A New High-Strength Powder Metallurgy Product, Materials and Methods,

Vol 23 (No 4), 1946, p 987-991

24 E.S Kopecki, Cemented Steels, Iron Age, Vol 157 (No 18), 1946, p 50-54

25 C.G Goetzel, Cemented Steels Infiltration Studies with Pure Iron and Copper Powders, Powder Metall Bull., Vol 1 (No 3), 1946, p 37-43

26 L Northcott and C.J Leadbeater, Sintered Iron-Copper Compacts, Symposium on Powder Metallurgy,

Special Report No 38, The Iron and Steel Institute, 1947, p 142-150

27 P Schwarzkopf, Infiltration of Powder Metal Compacts with Liquid Metal, Met Prog., Vol 57 (No 1),

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Vol 39, 1948, p 71-78

30 F.R Hensel, Treatment of Bearing, U.S Patent 2,364,713, 1941

31 E Fetz, Bearings from Metal Powder A New Art, Metals and Alloys, Vol 8 (No 9), 1937, p 257-260

32 E Fetz, Manufacture of Composite Bearings, U.S Patent 2,234,371, 1941

33 F.R Hensel, Impregnation of Metallic Composition with Bismuth, British Patent 590,412, 1947

34 A.L Boegehold, Copper-Nickel-Lead Bearings, Powder Metall., J Wulff, Ed., American Society for

Metals, 1942, p 520-529

35 F.R Hensel and E.I Larson, Sintered Porous Aluminum-Base Bearings, U.S Patent 2,418,841, 1947

36 F.R Hensel, Method of Making Porous Bearing Surfaces, U.S Patent 2,447,980, 1948

Because the two metal types do not alloy with one another, the rule of mixture can be applied to determine the density of

a specific composition Figure 8 shows the effect of increasing tungsten content on density, hardness, and electrical conductivity for copper-tungsten contact material (Ref 37) The straight-line relationship between volume ratio and conductivity is typical for this system Figure 9 shows the change in thermal expansion coefficient with tungsten content; principal mechanical properties versus tungsten content are plotted in Fig 10 (Ref 38) The boldface portions of the curves represent composition ranges of material that can be readily produced by infiltration with a low-melting metal content of approximately 10 to 40 vol% (5 to 25 wt%)

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Mixing of the component elemental powders, briquetting, sintering, subsequent working

Very fine, 1-50 •

Impregnation of the loosely filled tungsten powder in a mold, extrusion into shape Coarse, 100-400

Coarse, 100-400 Medium, 50-100

Dip impregnation of a pressed (and presintered) tungsten compact, machining to size

Very fine, 1-50

Fig 8 Effect of composition on physical properties of tungsten-copper contact material (a) Density (b)

Hardness (c) Electrical conductivity Heavy framed areas are composition ranges for liquid copper infiltration or sintering of compacts from mixtures Source: Ref 37

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Fig 9 Effect of composition on thermal expansion of tungsten-copper contact material Boldface portion of

curves designates liquid copper-infiltrated tungsten or sintered compacts from powder mixtures Light portion

of curves designates powder mixtures; compositions are not infiltrable Source: Ref 38

Fig 10 Effect of composition on mechanical properties of tungsten-copper contact material Boldface portion of

curves designates liquid copper-infiltrated tungsten or sintered compacts from powder mixtures Light portion

of curves designates powder mixtures; compositions are not infiltrable HRB Source: Ref 39

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Table 6 lists mechanical and electrical property data for tungsten-silver and molybdenum-silver contact materials (Ref 39) Also included are data for nickel-silver contact materials that can be produced by infiltration

Table 6 Properties of contact materials containing silver

Composition, wt% Transverse rupture strength Electrical conductivity

Ag W Mo Ni

Density, g/cm3

Hardness,

HB MPa ksi Mmho/cm %IACS

Estimated contact resistance(a)

(b) 30T68 Hardness, Rockwell Superficial

(c) 30T46 Hardness, Rockwell Superficial

In infiltrated materials, the soft conductor metal matrix is the minor constituent, and extrusion for profile generation is not practical except for nickel-silver composites All materials are readily machinable into a variety of shapes, especially caps, platelets, and rings Usually, the heavy-duty contact metal, as a facing, is joined by clamping or brazing onto a support structure The facing also may be penetrated by an infiltrant with a major portion, that on cooling, solidifies like a casting; an example is copper that is strengthened by small amounts of beryllium, chromium, or nickel and is cast into the form of a backing, arm, or other support structure

Primary applications for infiltrated tungsten-copper composites are resistance welding electrodes and make-and-break contact facings in oil or air circuit breakers or transformer taps Tungsten-silver contacts are used in switch gear and low-voltage regulators (Ref 37) Low contact resistance and nonsticking properties of nickel-silver contacts make them suitable for high-voltage disconnect switches (Ref 39) Porous, cup-shaped nickel compacts have been impregnated with mercury as part of a short circuiting safety switch contact in proximity fuses for radio-controlled detonation (Ref 40, 41)

Rocket Nozzles. The manufacture of silver-infiltrated tungsten contacts formed the basis for the development and production of large billets, from which rocket nozzle throat liners have been fabricated This material has proved successful in actual service in rockets of underwater-launched ballistic missiles (Ref 42) because:

• Extreme stability of the structure (virtually zero change in critical dimensions due to the temperature, high-pressure gaseous environment in the nozzle throat)

high-• High resistance to thermal shock during heating and cooling at the extremely high rates experienced by the throat surface in contact with rocket propulsion gas This in turn requires high tensile strength and resistance to high hoop stresses at the outer perimeter of the throat liner, as well a good thermal conductivity to provide adequate heat transfer to the backup structure

• Fabricability, especially machinability, on an economical production scale

• Optimum reliability and reproducibility of the nozzle throats in spite of their relatively large size, compared to similarly produced P/M parts in electrical switch gear

An additional advantage of using silver as the matrix metal is its relatively high vapor pressure Silver evaporation aids infiltration of large capillaries by forming deposits on the pore walls before the liquid metal enters individual pores Also,

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the exposed surface region of the throat liner is kept at a temperature considerably below that of the propulsion gas due to evaporative transpiration cooling (Ref 43)

Figure 11 shows a typical silver-infiltrated tungsten ring machined from a large billet that weighed nearly 90 kg (200 lb)

It contained about 80 vol% W; the conductor metal was uniformly dispersed throughout the entire cross section, filling all interconnected pores (Fig 12) Processing parameters, production details, and starting material characteristics are described in Ref 44 and 45

Fig 11 Silver-infiltrated tungsten billet for rocket nozzle throat liner Source: Ref 42

Fig 12 Microstructure of silver-infiltrated 80W-20Ag billet Angular microconstituents are silver 500× Source:

Ref 42

Toensing and Zalsman (Ref 44) have also reported on the effect of these parameters on mechanical properties at ambient and elevated temperatures Figure 13 shows the change in tensile strength with temperature for a tungsten skeleton with 20% pore volume before and after silver infiltration Data represent average values, but strengths as high as 620 to 700 MPa (90 to 100 ksi) have been reported As the melting temperature of the silver is approached, the strength of the composite converges with that of the tungsten skeleton Table 7 summarizes mechanical and physical properties of 20 vol% silver-infiltrated material for different test temperatures within the operating temperature range experienced by the throat liner during rocket propulsion (Ref 42)

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Table 7 Physical and mechanical properties of silver-infiltrated tungsten

Determined at strain rate of 50 m/mm/min (0.05 in./in./min) for 20 vol% Ag/80 vol% W+

strength

Ultimate tensile

strength

Ultimate shear

Fig 13 Effect of temperature on tensile strength of porous uninfiltrated and silver-infiltrated (20 vol%)

tungsten Source: Ref 44

Jet Engine Components. The quest for materials to withstand the high temperatures and stresses imposed by combustion gases in the gas turbines of jet engines led to the development of cermets in the late 1940s and early 1950s Cermets offered increased operating temperatures and engine efficiency when used in rotating blades Their inherent brittleness prevented the use of cermets for this purpose, however, and their use for stationary gas-conducting nozzle vanes also failed to win acceptance For more information, see the article "Cermets and Cemented Carbides" in this Volume

To overcome brittleness, the infiltration process was applied to the production of gas turbine components Sintered and preformed titanium carbide skeletons were infiltrated with a nickel-or cobalt-base superalloy in a vacuum Graded products that had the following structural characteristics were produced:

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• Ductile and tough roots and airfoil tips containing nearly 100% superalloy that withstood combined tensile and bend stresses at moderately high temperatures

• Ductile and tough superalloy-rich leading and trailing edges that resisted impact from small solid particles at temperatures ranging from ambient to operational

• Strong, creep-resistant airfoil portions containing 60 to 80 vol% titanium carbide that withstood the centrifugal force-induced tensile stresses at the highest temperature zones near the radial centroid of the foil, about midway between the root and tip

• Oxidation-protective, ductile, superalloy-rich airfoil encasements integrally joined with the metallic matrix

Figure 14(a) shows a graded turbine bucket for a J-47 jet engine after infiltration Figure 14(b) shows the graded turbine bucket after machining of the root configuration The change in microstructure across the airfoil is shown in Fig 15 (Ref 43) Table 8 gives stress-rupture for different zones of the graded bucket (Ref 43, 49) Other infiltrated titanium carbide turbine components are shown in Fig 16

Table 8 Stress-rupture properties of infiltrated graded cermet bucket

Airfoil tip Superalloy-rich region 870-930 1600-1700 55 8 870 1600 138 20

Airfoil body Superalloy-infiltrated TiC 1000 1800 70-100 10-15 980 1800 83 12

Fig 14 Graded cermet turbine blade (a) After superalloy infiltration of titanium carbide skeleton (b) After

machining of root

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Fig 15 Microstructure of graded turbine blade across airfoil Angular and rounded microconstituents are

titanium carbide 150× Source: Ref 43

Fig 16 Infiltrated titanium carbide cermet jet engine turbine components (a) J-35 nozzle vane (b)

Experimental hollow vane (c) J-57 turbine bucket (d) J-47 turbine bucket

While these infiltrated carbide turbine components, like their sintered cermet counterparts, did not reach commercial production, blades for several stages of the compressor for a J-33 jet engine were mass produced from copper alloy infiltrated steel compacts (Ref 50) These blades were heat treated to a yield strength of 620 MPa (90 ksi), with an

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elongation of 5%, and withstood three to four times as much vibration at an operating temperature of 370 °C (700 °F) as blades for these stages made from martensitic type 403 stainless steel precision forgings

Tools. In parallel development with turbine blades, titanium carbide skeletons were infiltrated with a variety of liquid steel alloys to manufacture tools and wear-resistant parts The infiltrant varied from simple low-carbon steel to alloy and high-speed steels (Ref 51) Angular or rounded titanium carbide grains resulted, depending on carbide content and matrix composition Infiltrated materials can be heat treated to produce specific properties For instance, hardness ranged from 90.1 to 90.6 HRA after water quenching and from 86.0 to 90.3 HRA after tempering At temperatures up to 750 °C (1380

°F), hot hardness for the titanium carbide that was infiltrated with type T6 tungsten high-speed steel was equivalent to commercial grades of cemented carbides This material had better oxidation resistance than cemented carbides up to 870

°C (1600 °F) and room-temperature transverse-rupture strengths up to 1500 MPa (220 ksi) Cutting speeds were twice those of molybdenum high-speed steel, one and one-half times those of Stellite, but only one fourth those of commercial steel-cutting grades of cemented carbides

Because the solubility of titanium carbide in liquid steel is high, the rate of infiltration is slowed so that penetration of the liquid tends to be confined to the regions near the original contact face The remaining porosity cannot be filled because

of diffusion solidification, regardless of the time allowed for penetration of the liquid As a result, severe size limitations are required for the infiltrated product to be sound and uniform in structure This disadvantage has caused the substitution

of in situ liquid-phase sintering of titanium carbide and steel powder mixtures in the production of such tool materials For more information, see the article "Cermets and Cemented Carbides" in this Volume

Mechanical Parts. Infiltration is widely used in the production of ferrous structural parts requiring densities in excess

of 7.4 g/cm3 and mechanical properties superior to those obtained by compacting, sintering, and coining Depending on the application, porous skeletons of iron or steel can be fully or partially infiltrated with copper alloy

There are several advantages to infiltration of iron-base structural parts with copper alloys (Ref 52):

Increased mechanical properties Higher tensile strengths and hardnesses, greater impact energies, and

fatigue strengths are obtained through infiltration Figure 17 shows the effect of infiltration on strength

Uniform density Parts that contain non-uniform and/or heavy sections can be infiltrated to obtain more

uniform density; infiltration tends to even out density variations

Higher density Infiltration is a useful method to increase sintered part weight without increasing the

size of the part Given the press size limitations and restrictions in pressing technique and powder compressibility, it is often easier to obtain high density through infiltration Certainly, when considering normal P/M operations, it would be difficult to obtain densities in excess of 7.2 g/cm3 without resorting

to additional pressing and sintering operations Infiltration makes densities in excess of 7.2 g/cm3possible in a single pressing and sintering operation

Removal of porosity for secondary operations Infiltration can be used in place of impregnation as a

method to seal surface porosity so that secondary operations such as pickling and plating can be performed without damaging the interior of the part and creating subsequent "bleeding" problems It is also a method of sealing a part used for applications in which no porosity is desired

Selective property variation It is possible by infiltrating only selected areas of a part to obtain, within

limits, a controlled variation of properties in the part for example, variations in density, strength, and hardness This is known as localized infiltration Infiltration to considerably less than the full density in the part (e.g., 7.1 g/cm3) is known as starve infiltration

Assembly of multiple parts Different sections of the final part, pressed separately, can be assembled by

sintering the individual pieces together and bonding the pieces into one part through common infiltration

Trang 20

Fig 17 Effect of infiltration on transverse-rupture strength of iron-carbon alloys sintered to a density of 6.4

g/cm 3 Combined carbon in alloys was about 80% of graphite added to iron powder; amount of copper infiltrant was adjusted to fill various fractions of void space Source: Ref 53

Table 9 gives composition and typical properties of P/M infiltrated steels

Table 9 Composition and properties of P/M infiltrated steels

MPIF composition limits(b), %

80.5-830 120 740 107 1.0 9.5 7.0 35 HRC 135 20

AS 0.6-1.0

8.0-14.9

91.4

80.1-895 130 725 105 60.5 9.5 7.0 40 HRC 135 20

FX-2000 (d) AS 0.3 max

15.0-25.0

85.0

70.7-450 65 1.0 20 15 60 HRB

AS 0.3-0.6

15.0-25.0

84.7

70.4-790 115 655 95 <0.5 8.1 6.0 30 HRC 125 18

AS 0.6-1.0

15.0-25.0

84.4

70.0-860 125 740 107 <0.5 6.8 5.0 42 HRC 125 18

Trang 21

Note: All materials have a density range of 7.2 to 7.6 g/cm

(a) AS, as sintered; HT, heat treated (typically austenitized at 870 °C (1600 °F)), oil quenched and tempered 1

h at 200 °C (390 °F)

(b) MPIF Standards require that the total amount of all other elements be <2.0%

The usual method of infiltrating iron and steel skeletons is to place a compact pressed from the powder of the infiltrant material next to the skeleton The compact of infiltrant powder can be positioned on top or underneath the skeleton compact, or two infiltrant compacts can be used one on top, the other underneath the skeleton compact The exact amount of infiltrant needed can be compacted in the same die in which the powder for the porous skeleton is pressed

After the skeleton has been sintered, the green compact or compacts of infiltrant powder are positioned next to the skeleton and the assembly heated to the infiltration temperature Sintering of the skeleton and infiltration can be combined into one operation, in which the green compact or compacts of the infiltrant are positioned next to the green compact of the skeleton By controlling the rate of heating, the skeleton compact will be adequately sintered by the time the melting point of the infiltrant is reached This operation is called "sintrating."

If only part of the porous skeleton is to be infiltrated for example, the teeth of an infiltrated gear the skeleton can be positioned in a graphite container in which space is provided adjacent to the gear teeth to be preferentially infiltrated This space is then filled with the appropriate amount of infiltrant in powder form Because iron has some solubility in copper, the liquid infiltrant will attack the surface of the skeleton when it first comes in contact with it, and severe erosion can take place at this point One method to minimize erosion is to use a copper alloy (e.g., 80%Cu-20%Zn brass) as infiltrant Because the brass does not melt at one temperature, but over a range of temperatures, less erosion takes place

Another method is to use an alloy of copper with iron as an infiltrant However, it is difficult to specify the exact amount

of iron; too little iron can cause erosion, and too much iron can cause an undesirable adherent deposit on the infiltrated part A third method is to use an alloy of copper, iron, and a third alloying constituent, such as manganese, which oxidizes

in the atmosphere in which infiltration takes place In this case, a crust containing an oxide of the oxidizing alloying ingredient of the infiltrant is formed, which does not adhere to the skeleton but which can be more or less readily removed

Figure 18 shows a small foot holder that required strength, machinability for tapping a thread, and plateability These characteristics were achieved by infiltrating a sintered iron-rich skeleton (7% Cu) with a copper-rich alloy containing 5%

Mn and 5% Fe The compacts were infiltrated under furnace conditions similar to those used for sintering, using infiltrating slugs previously pressed The infiltrated parts were electroplated with chromium to a satin finish Processing details for the two-step procedure are given in the table that accompanies Fig 18

Trang 22

Press and tool details

Type of press Mechanical(a)

Press capacity 45.4 metric tons (50 tons)

Die material Tungsten carbide (6% Co)

Punch material D2 tool steel

Core-rod material Tungsten carbide (6% Co)

Processing details

Compacting pressure: 415 MPa (60 ksi)

Infiltrating slugs 276 MPa (40 ksi)

Preheating treatment 15 min at 1100 °C (2040 °F)

Sintering treatment 15 min at 1100 °C (2040 °F)

Infiltrating treatment 15 min at 1100 °C (2040 °F)

Atmosphere for sintering and infitrating Endothermic

(a) Two movements above and three below

Fig 18 Small compact infiltrated with copper alloy to provide machinability, strength, and plateability

The control of dimensions during infiltration can cause problems It depends on the composition of the steel; carbon-free iron shows the greatest growth during infiltration It also depends on the exact temperature of infiltration and the time during which the infiltrated compact is above the liquidus temperature of the infiltrant

Bearings. The best example for the industrial use of infiltration in the bearing field is strip-backed steel, precision-type main, and connecting rod bearings for automobiles In this application, the anti-friction babbitt alloy is used to infiltrate the pores of a skeletal cupronickel strip that is bonded to the steel backing and produces an extra layer on the surface facing the crankpin (Ref 7, 34)

Infiltration techniques can also be applied to high-temperature bearing materials, such as bearing retainers in gas turbines for supersonic aircraft To combat the high wear of these cages, an ideal structure consists of a hard, load-bearing phase

Trang 23

intertwined with a liquid metallic lubricant Structures that closely approach the ideal concept and operate up to 370 °C (700 °F) have been developed (Ref 53)

Materials exhibiting improved anti-friction properties against steel under simulated service conditions involving very high rotational speeds are efficiently fabricated by P/M techniques that include an infiltration step These materials are characterized by a duplex structure (a soft, metallic phase of about 15 vol%) that is uniformly dispersed throughout the hard matrix The matrix can be either Monel or a 48Ni-48Cr-4Si alloy, with 10 wt% molybdenum disilicide added in some cases to reduce wear The soft phase consists of silver that is infiltrated after sintering the hard alloy powder compact

References cited in this section

7 T Kimura, J.C Kosco, and A.J Shaler, Detergency During Infiltration in Powder Metallurgy, Proc of 15th Annual Meeting, Metal Powder Industries Federation, 1959, p 56-66

8 R Kieffer and F Benesovsky, The Production and Properties of Novel Sintered Alloys (Infiltrated Alloys),

Berg- und Hüttenmännische Monatshefte, Vol 94 (No 8/9), 1949, p 284-294

34 A.L Boegehold, Copper-Nickel-Lead Bearings, Powder Metall., J Wulff, Ed., American Society for

Metals, 1942, p 520-529

37 R Kieffer and W Hotop, Powder Metallurgy and Sintered Materials, Springer-Verlag, 1943, p 324-326,

329

38 F.R Hensel, E.I Larsen, and E.F Swazy, Physical Properties of Metal Compositions with a Refractory

Metal Base, Powder Metall., J Wulff, Ed., American Society for Metals, 1942, p 483-492

39 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 207-209, 216-217

40 P Schwarzkopf, Powder Metallurgy, Macmillan, 1947, p 167-168

41 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 539-540, 634

42 C.G Goetzel and J.B Rittenhouse, The Influence of Processing Conditions on the Properties of

Silver-Infiltrated Tungsten, Symposium sur la Métallurgie des Poudres, Edictions Métaux (Paris), 1964, p 279-288

43 C.G Goetzel and H.W Lavendel, Infiltrated Powder Components for Power Plant and Propulsion Systems,

Metals for the Space Age, Plansee Proceedings 1964, F Benesovsky, Ed., Springer-Verlag, 1965, p

46 J.R Kattus, Report, 5525-1428 II, Southern Research Institute, 19 Sept 1962

47 J.R Kattus, Report, 6253-1526 VI, Southern Research Institute, 9 Dec 1963

48 J.R Kattus, Report, 6606-1498 XI, Southern Research Institute, 31 Jan 1964

49 H.W Lavendel and C.G Goetzel, "A Study of Graded Cermet Components for High Temperature Turbine Applications," Report, WADC-TR 57-135, May 1957

50 G Stern and J.A Gerzina, Making Jet Engine Compressor Blades by Powder Metallurgy, Iron Age, Vol

165 (No 8), 1950, p 74-77

51 C.G Goetzel and L.P Skolnick, Some Properties of a Recently Developed Hard Metal Produced by

Infiltration, Sintered High-Temperature and Corrosion-Resistant Materials Plansee Proc., F Benesovsky,

Ed., Pergamon Press, 1956, p 92-98

52 C Durdaller, "Copper Infiltration of Iron-Based P/M Parts," Hoeganaes Corp., Riverton, NJ, 1969

53 J.T Burwell, Wear Behavior of High Temperature Bearing Materials, Prec Met Mold., Vol 14 (No 10),

1956, p 40, 41, 87, 88, 90, 91

Trang 24

on the latter topics is given in "Selected References" at the end of this article

Mechanism of Infiltration

Analytical treatments to describe fluid flow and heat transfer during infiltration of porous preforms by a liquid metal have been addressed by different groups at MIT (Ref 54, 55, 56, 57, 58, 59, 60, 61) and Colorado School of Mines (Ref 62) in the United States, also in England (Ref 63), France (Ref 64), Japan (Ref 65), China (Ref 66), and Jordan (Ref 67) General expressions have been derived to describe heat, mass, fluid flow, and kinetics during the infiltration process A review of theoretical factors and mechanisms dealing with infiltration of a porous body by a liquid metal is given in Ref

68 Factors that control the matrix grain size, interfacial reactions, and morphology of the fiber-matrix interface and its stability have been predicted (e.g., initial fiber temperature, preform compressibility, reaction heat, external cooling, or reaction kinetics) (Ref 54, 57, 59, 70) Infiltration kinetics, size of the remelting region, and temperature distributions can

be calculated (Ref 54, 58, 61, 62, 65, 70)

Models for pressure effects in conventional or new infiltration processes (squeeze casting or chemical vapor infiltration) have been developed (Ref 54, 57, 60, 61, 67, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80) Based on the analysis of physical phenomena that govern the infiltration process, good practical guidelines to optimize the processing techniques and the materials produced can be found in Ref 75

The mechanism of wetting and spreading of the liquid metal has been studied (Ref 54, 78, 81, 82) These studies reveal the formation of a precursor film ahead of the bulk liquid front by adsorption, condensation, and surface migration on the solid wall (Ref 82) A model for chemical vapor infiltration is presented in Ref 83 and 84

Sensors and models apparatuses (e.g., noninvasive capacitance technique), model experiments, and instrumented casting facilities have been developed to confirm theoretical predictions (Ref 55, 56, 58, 60, 64, 78, 81, 85, 86, 87) Modeling of magnetic field assisted and ultrasonic infiltration also has been attempted (Ref 88, 89, 90) A validation of the Lorenz force model has been experimentally obtained (Ref 88)

References cited in this section

54 A Mortensen, L.J Masur, J.A Cornie, and M.C Flemings, Infiltration of Fibrous Preforms by a Pure

Metal, Part I: Theory, Metall Trans A, Vol 20, 1989, p 2535-2547

55 J Masur, A Mortensen, J.A Cornie, and M.C Flemings, Infiltration of Fibrous Preforms by a Pure Metal,

Part II: Experiment, Metall Trans A, Vol 20, 1989, p 2549-2557

56 A Mortensen, Infiltration of Fibrous Preforms by a Pure Metal, Part III: Capillary Phenomena, Metall Trans A, Vol 21, 1990, p 2257-2263

57 A Mortensen and V.J Michaud, Infiltration of Fiber Preforms by a Binary Alloy, Part I: Theory, Metall Trans A, Vol 21, 1990, p 2059-2072

58 V.J Michaud and A Mortensen, Infiltration of Fiber Preforms by a Binary Alloy, Part II: Further Theory

and Experiments, Metall Trans A, Vol 23, 1992, p 2263-2280

59 R.B Calhoun and A Mortensen, Infiltration of Fibrous Preforms by a Pure Metal, Part IV: Morphological

Trang 25

Stability of the Remelting Front, Metall Trans A, Vol 23, 1992, p 2291-2299

60 V.J Michaud, L.M Compton, and A Mortensen, Capillarity in Isothermal Infiltration of Alumina Fiber

Preforms with Aluminum, Metall Trans A, Vol 25, 1994, p 2145-2152

61 A Mortensen and J.A Cornie, On the Infiltration of Metal Matrix Composites, Metall Trans A, Vol 18,

1987, p 1160-1163

62 G.P Martins, D.L Olson, and G.R Edwards, Modeling of Infiltration Kinetics for Liquid Metal Processing

of Composites, Metall Trans B, Vol 19, 1988, p 95-101

63 R.M.K Young, Liquid Metal Infiltration Model of Unidirectional Fiber Preform in Inert Atmospheres,

Mater Sci Eng A, Vol 135, 1991, p 19-22

64 E Lacoste, M Aboulfatah, M Danis, and F Girot, Numerical Simulation of the Infiltration of Fibrous

Preforms by a Pure Metal, Metall Trans A, Vol 24, 1993, p 2667-2678

65 M Yokota, Basis and Application of Infiltration Techniques for Powder Metallurgy, J Jpn Soc Powder Powder Metall., Vol 38, 1991, p 464-471

66 L Hu, S Luo, and W Huo, Determination of Threshold Pressure for Infiltration of Liquid Aluminum into

Short Alumina Fiber Preform, Trans Nonferrous Met Soc China, Vol 6, 1996, p 133-137

67 A.E.M Assarand and M.A Alnimr, Fabrication of Metal Matrix Composites by Infiltration Process, Part I:

Modeling of Thermodynamic and Thermal Behavior, J Compos Mater., Vol 28, 1994, p 1480-1490

68 R Lumpkins, Theoretical Review of the Copper Infiltration of P/M Components, Powder Metall Int., Vol

17, 1985, p 120-123

70 X Tong and J.A Kahn, Infiltration and Solidification/Remelting of a Pure Metal in a Two-Dimensional

Porous Preform, J Heat Transfer (Trans AIME), Vol 118, 1996, p 173-180

71 T.W Cline and J.F Mason, Squeeze Infiltration Process of Metal-Matrix Composites, Metall Trans A, Vol

18, 1987, p 1519-1530

72 S Nourbakhsh, F.-L Liang, and H Margolin, Calculation of Minimum Pressure for Liquid Metal

Infiltration of a Fiber Array, Metall Trans A, Vol 20, 1985, p 1861-1866

73 N.H Tai and T.W Chou, Modeling of an Improved Chemical Vapor Infiltration Process for Ceramic

Composites Fabrication, J Am Ceram Soc., Vol 73, 1990, p 1489-1498

74 Z.H Xia, Y.H Zhou, Z.Y Mao, and B.L Shang, Fabrication of Fiber-Reinforced Metal Matrix Composites

by Variable Pressure Infiltration, Metall Trans B, Vol 23, 1992, p 295-302

75 A Mortensen, V.J Michaud, and M.C Flemings, Pressure-Infiltration Processing of Reinforced Aluminum,

JOM, Vol 45, 1993, p 36-43

76 H You, M.G Bader, Z Zhang, S Fox, and H.M Flower, Heat Flow Analysis of the Squeeze Casting of

Metal-Matrix Composites, Compos Manuf., Vol 5, 1994, p 105-112

77 S Long, Z Zhang, and H.M Flower, Infiltration and Wetting of Liquid Infiltration of Unidirectional Fiber

Arrays by Squeeze Casting, Acta Mater., Vol 42, 1994, p 1389-1397

78 T.R Jonas, J.A Cornie, and K.C Russell, Infiltration and Wetting of Alumina Particulate by Aluminum

and Aluminum-Magnesium Alloys, Metall Trans A, Vol 26, 1995, p 1491-1497

79 S Long, Z Zhang, and H.M Flower, Characterization of Liquid Metal Infiltration of a Chopped Fiber

Preform Aided by External Pressure, Parts I-III, Acta Mater., Vol 43, 1995, p 3489-3509; Vol 44, 1996, p

4233-4240

80 T Yamauchi and Y Nishida, Consideration on Suitable Infiltration Conditions for Molten Metal into

Fibrous Preforms, J Jpn Inst Light Met., Vol 45, 1995, p 409-414

81 J.-H Ahn, N Terao, and A Berghezan, Experimental Factors on Wetting and Infiltration Fronts in Metals,

Scr Mater., Vol 22, 1988, p 793-796

82 J.-H Ahn and A Berghezan, Scanning Electron Microscopy of Liquid Metal Infiltration of Capillaries,

Mater Sci Technol., Vol 7, 1991, p 643-648

83 R.P Courier and S.M Valone, Time-Dependent Solution to the Tai-Chou Chemical Vapor Infiltration

Model, J Am Ceram Soc., Vol 73, 1990, p 1758-1759

84 T.L Starr and A.W Smith, 3-D Modeling of Forced-Flow Thermal-Gradient CVI for Ceramic Composite

Trang 26

Fabrication in Chemical Vapor Deposition on Refractory Metals and Ceramics, T.M Besmann and B.M

Gallois, Ed., Mater Res Soc., 1990, p 55-60

85 T.R Fletcher, J.A Cornie, and K.C Russell, Capacitance Technique for Studying Pressure Infiltration,

Mater Sci Eng A, Vol 144, 1991, p 159-163

86 R Asthana and P.K Rohatgi, Melt Infiltration of Silicon Carbide Compacts, Z Metallkd., Vol 83, 1992, p

89 H Nakanishi, Y Tsunekawa, N Mohri, and I Niimi, Ultrasonic Infiltration in Alumina Particle/Molten

Aluminum System, J Jpn Inst Light Met., Vol 43, 1993, p 14-19

90 Y Tsunekawa, H Nakanishi, M Okumiya, and N Mohri, Application of Ultrasonic Vibration to Molten

Aluminum Infiltration, Key Eng Mater., Vol 104-107, 1995, p 215-224

Infiltration

Claus G Goetzel, Stanford University, and Joanna Groza, University of California, Davis

References

1 P Schwarzkopf, The Mechanism of Infiltration, Symposium on Powder Metallurgy, 1954, Special Report

No 58, The Iron and Steel Institute, London, 1956, p 55-58

2 K.A Semlak, C.W Spencer, and F.N Rhines, Rate of Capillary Rise of Liquid Metal in a High Melting

Metal Powder Compact, Trans AIME, Vol 209, 1957, p 63-64

3 K.A Semlak and F.N Rhines, The Rate of Infiltration in Metals, Trans AIME, Vol 212, 1958, p 325-331

4 W.D Jones, Fundamental Principles of Powder Metallurgy, Edward Arnold, 1960, p 505-512

5 C.G Goetzel and A.J Shaler, Mechanism of Infiltration of Porous Powder Metallurgy Parts, J Met., Vol 16

8 R Kieffer and F Benesovsky, The Production and Properties of Novel Sintered Alloys (Infiltrated Alloys),

Berg- und Hüttenmännische Monatshefte, Vol 94 (No 8/9), 1949, p 284-294

9 C.G Goetzel, Infiltration Metallurgy, Research, Vol 4 (No 12), 1951, p 555-561

10 F.V Lend, Powder Metallurgy, Metal Powder Industries Federation, 1980, p 313-319

11 G Matsumura, Stress Infiltration in Two-Phase Alloys, P1anseeberi Pulvermetall., Vol 8 (No 3), 1960, p

110-118

12 W.A Kaysser, S Takajo, and G Petzow, Skeleton Dissolution and Skeleton Formation During Liquid

Phase Sintering of Fe-Cu, Modern Development in Powder Metallurgy, Vol 12, Metal Powder Industries

Federation, 1981, p 473-482

13 H.W Lavendel and C.G Goetzel, Recent Advances in Infiltrated Titanium Carbides, High Temperature Materials, R.F Hehemann and G.M Ault, Ed., John Wiley & Sons, 1959, p 140-154

14 G Langford, High Speed Steel Made by Liquid Infiltration, Mater Sci Eng., Vol 28, 1977, p 275-284

15 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 196

16 K Schröter, Border Regions of Metallography, Z Metallkd., Vol 23 (No 7), 1931, p 197-201

Trang 27

17 J.M Krol and C.G Goetzel, "Refractory Metal Reinforced Super Alloys," USAF Technical Report 5892, ATI No 57154, May 1949

18 F.V Lend, Powder Metallurgy, Metal Powder Industries Federation, 1980, p 383-400

19 R Kieffer and F Kölbl, Production of Hard Metals by Infiltration, Berg Hüttenmämann Monatsh., Vol 95

22 C.L Gebauer, Process of Producing Metal Bodies, U.S Patent 1,342,801, 1920; C.L Gebauer, Production

of a Composite Metallic Article, U.S Patent 1,395,269, 1921

23 F.P Peters, Cemented Steels A New High-Strength Powder Metallurgy Product, Materials and Methods,

Vol 23 (No 4), 1946, p 987-991

24 E.S Kopecki, Cemented Steels, Iron Age, Vol 157 (No 18), 1946, p 50-54

25 C.G Goetzel, Cemented Steels Infiltration Studies with Pure Iron and Copper Powders, Powder Metall Bull., Vol 1 (No 3), 1946, p 37-43

26 L Northcott and C.J Leadbeater, Sintered Iron-Copper Compacts, Symposium on Powder Metallurgy,

Special Report No 38, The Iron and Steel Institute, 1947, p 142-150

27 P Schwarzkopf, Infiltration of Powder Metal Compacts with Liquid Metal, Met Prog., Vol 57 (No 1),

30 F.R Hensel, Treatment of Bearing, U.S Patent 2,364,713, 1941

31 E Fetz, Bearings from Metal Powder A New Art, Metals and Alloys, Vol 8 (No 9), 1937, p 257-260

32 E Fetz, Manufacture of Composite Bearings, U.S Patent 2,234,371, 1941

33 F.R Hensel, Impregnation of Metallic Composition with Bismuth, British Patent 590,412, 1947

34 A.L Boegehold, Copper-Nickel-Lead Bearings, Powder Metall., J Wulff, Ed., American Society for

Metals, 1942, p 520-529

35 F.R Hensel and E.I Larson, Sintered Porous Aluminum-Base Bearings, U.S Patent 2,418,841, 1947

36 F.R Hensel, Method of Making Porous Bearing Surfaces, U.S Patent 2,447,980, 1948

37 R Kieffer and W Hotop, Powder Metallurgy and Sintered Materials, Springer-Verlag, 1943, p 324-326,

329

38 F.R Hensel, E.I Larsen, and E.F Swazy, Physical Properties of Metal Compositions with a Refractory

Metal Base, Powder Metall., J Wulff, Ed., American Society for Metals, 1942, p 483-492

39 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 207-209, 216-217

40 P Schwarzkopf, Powder Metallurgy, Macmillan, 1947, p 167-168

41 C.G Goetzel, Treatise on Powder Metallurgy, Vol 2, Interscience, 1950, p 539-540, 634

42 C.G Goetzel and J.B Rittenhouse, The Influence of Processing Conditions on the Properties of

Silver-Infiltrated Tungsten, Symposium sur la Métallurgie des Poudres, Edictions Métaux (Paris), 1964, p 279-288

43 C.G Goetzel and H.W Lavendel, Infiltrated Powder Components for Power Plant and Propulsion Systems,

Metals for the Space Age, Plansee Proceedings 1964, F Benesovsky, Ed., Springer-Verlag, 1965, p

Trang 28

46 J.R Kattus, Report, 5525-1428 II, Southern Research Institute, 19 Sept 1962

47 J.R Kattus, Report, 6253-1526 VI, Southern Research Institute, 9 Dec 1963

48 J.R Kattus, Report, 6606-1498 XI, Southern Research Institute, 31 Jan 1964

49 H.W Lavendel and C.G Goetzel, "A Study of Graded Cermet Components for High Temperature Turbine Applications," Report, WADC-TR 57-135, May 1957

50 G Stern and J.A Gerzina, Making Jet Engine Compressor Blades by Powder Metallurgy, Iron Age, Vol

165 (No 8), 1950, p 74-77

51 C.G Goetzel and L.P Skolnick, Some Properties of a Recently Developed Hard Metal Produced by

Infiltration, Sintered High-Temperature and Corrosion-Resistant Materials Plansee Proc., F Benesovsky,

Ed., Pergamon Press, 1956, p 92-98

52 C Durdaller, "Copper Infiltration of Iron-Based P/M Parts," Hoeganaes Corp., Riverton, NJ, 1969

53 J.T Burwell, Wear Behavior of High Temperature Bearing Materials, Prec Met Mold., Vol 14 (No 10),

1956, p 40, 41, 87, 88, 90, 91

54 A Mortensen, L.J Masur, J.A Cornie, and M.C Flemings, Infiltration of Fibrous Preforms by a Pure

Metal, Part I: Theory, Metall Trans A, Vol 20, 1989, p 2535-2547

55 J Masur, A Mortensen, J.A Cornie, and M.C Flemings, Infiltration of Fibrous Preforms by a Pure Metal,

Part II: Experiment, Metall Trans A, Vol 20, 1989, p 2549-2557

56 A Mortensen, Infiltration of Fibrous Preforms by a Pure Metal, Part III: Capillary Phenomena, Metall Trans A, Vol 21, 1990, p 2257-2263

57 A Mortensen and V.J Michaud, Infiltration of Fiber Preforms by a Binary Alloy, Part I: Theory, Metall Trans A, Vol 21, 1990, p 2059-2072

58 V.J Michaud and A Mortensen, Infiltration of Fiber Preforms by a Binary Alloy, Part II: Further Theory

and Experiments, Metall Trans A, Vol 23, 1992, p 2263-2280

59 R.B Calhoun and A Mortensen, Infiltration of Fibrous Preforms by a Pure Metal, Part IV: Morphological

Stability of the Remelting Front, Metall Trans A, Vol 23, 1992, p 2291-2299

60 V.J Michaud, L.M Compton, and A Mortensen, Capillarity in Isothermal Infiltration of Alumina Fiber

Preforms with Aluminum, Metall Trans A, Vol 25, 1994, p 2145-2152

61 A Mortensen and J.A Cornie, On the Infiltration of Metal Matrix Composites, Metall Trans A, Vol 18,

1987, p 1160-1163

62 G.P Martins, D.L Olson, and G.R Edwards, Modeling of Infiltration Kinetics for Liquid Metal Processing

of Composites, Metall Trans B, Vol 19, 1988, p 95-101

63 R.M.K Young, Liquid Metal Infiltration Model of Unidirectional Fiber Preform in Inert Atmospheres,

Mater Sci Eng A, Vol 135, 1991, p 19-22

64 E Lacoste, M Aboulfatah, M Danis, and F Girot, Numerical Simulation of the Infiltration of Fibrous

Preforms by a Pure Metal, Metall Trans A, Vol 24, 1993, p 2667-2678

65 M Yokota, Basis and Application of Infiltration Techniques for Powder Metallurgy, J Jpn Soc Powder Powder Metall., Vol 38, 1991, p 464-471

66 L Hu, S Luo, and W Huo, Determination of Threshold Pressure for Infiltration of Liquid Aluminum into

Short Alumina Fiber Preform, Trans Nonferrous Met Soc China, Vol 6, 1996, p 133-137

67 A.E.M Assarand and M.A Alnimr, Fabrication of Metal Matrix Composites by Infiltration Process, Part I:

Modeling of Thermodynamic and Thermal Behavior, J Compos Mater., Vol 28, 1994, p 1480-1490

68 R Lumpkins, Theoretical Review of the Copper Infiltration of P/M Components, Powder Metall Int., Vol

17, 1985, p 120-123

69 S.G Warrier and R.Y Lin, Interaction between SiC Fibers and a Titanium Alloy during Infrared Liquid

Infiltration, Metall Trans A, Vol 26, 1995, p 1885-1894

70 X Tong and J.A Kahn, Infiltration and Solidification/Remelting of a Pure Metal in a Two-Dimensional

Porous Preform, J Heat Transfer (Trans AIME), Vol 118, 1996, p 173-180

71 T.W Cline and J.F Mason, Squeeze Infiltration Process of Metal-Matrix Composites, Metall Trans A, Vol

18, 1987, p 1519-1530

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72 S Nourbakhsh, F.-L Liang, and H Margolin, Calculation of Minimum Pressure for Liquid Metal

Infiltration of a Fiber Array, Metall Trans A, Vol 20, 1985, p 1861-1866

73 N.H Tai and T.W Chou, Modeling of an Improved Chemical Vapor Infiltration Process for Ceramic

Composites Fabrication, J Am Ceram Soc., Vol 73, 1990, p 1489-1498

74 Z.H Xia, Y.H Zhou, Z.Y Mao, and B.L Shang, Fabrication of Fiber-Reinforced Metal Matrix Composites

by Variable Pressure Infiltration, Metall Trans B, Vol 23, 1992, p 295-302

75 A Mortensen, V.J Michaud, and M.C Flemings, Pressure-Infiltration Processing of Reinforced Aluminum,

JOM, Vol 45, 1993, p 36-43

76 H You, M.G Bader, Z Zhang, S Fox, and H.M Flower, Heat Flow Analysis of the Squeeze Casting of

Metal-Matrix Composites, Compos Manuf., Vol 5, 1994, p 105-112

77 S Long, Z Zhang, and H.M Flower, Infiltration and Wetting of Liquid Infiltration of Unidirectional Fiber

Arrays by Squeeze Casting, Acta Mater., Vol 42, 1994, p 1389-1397

78 T.R Jonas, J.A Cornie, and K.C Russell, Infiltration and Wetting of Alumina Particulate by Aluminum

and Aluminum-Magnesium Alloys, Metall Trans A, Vol 26, 1995, p 1491-1497

79 S Long, Z Zhang, and H.M Flower, Characterization of Liquid Metal Infiltration of a Chopped Fiber

Preform Aided by External Pressure, Parts I-III, Acta Mater., Vol 43, 1995, p 3489-3509; Vol 44, 1996, p

4233-4240

80 T Yamauchi and Y Nishida, Consideration on Suitable Infiltration Conditions for Molten Metal into

Fibrous Preforms, J Jpn Inst Light Met., Vol 45, 1995, p 409-414

81 J.-H Ahn, N Terao, and A Berghezan, Experimental Factors on Wetting and Infiltration Fronts in Metals,

Scr Mater., Vol 22, 1988, p 793-796

82 J.-H Ahn and A Berghezan, Scanning Electron Microscopy of Liquid Metal Infiltration of Capillaries,

Mater Sci Technol., Vol 7, 1991, p 643-648

83 R.P Courier and S.M Valone, Time-Dependent Solution to the Tai-Chou Chemical Vapor Infiltration

Model, J Am Ceram Soc., Vol 73, 1990, p 1758-1759

84 T.L Starr and A.W Smith, 3-D Modeling of Forced-Flow Thermal-Gradient CVI for Ceramic Composite Fabrication in Chemical Vapor Deposition on Refractory Metals and Ceramics, T.M Besmann and B.M

Gallois, Ed., Mater Res Soc., 1990, p 55-60

85 T.R Fletcher, J.A Cornie, and K.C Russell, Capacitance Technique for Studying Pressure Infiltration,

Mater Sci Eng A, Vol 144, 1991, p 159-163

86 R Asthana and P.K Rohatgi, Melt Infiltration of Silicon Carbide Compacts, Z Metallkd., Vol 83, 1992, p

89 H Nakanishi, Y Tsunekawa, N Mohri, and I Niimi, Ultrasonic Infiltration in Alumina Particle/Molten

Aluminum System, J Jpn Inst Light Met., Vol 43, 1993, p 14-19

90 Y Tsunekawa, H Nakanishi, M Okumiya, and N Mohri, Application of Ultrasonic Vibration to Molten

Aluminum Infiltration, Key Eng Mater., Vol 104-107, 1995, p 215-224

Infiltration

Claus G Goetzel, Stanford University, and Joanna Groza, University of California, Davis

Selected References

Infiltration Techniques

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• Lorentz-Force-Driven Infiltration by Aluminum, R.M Andrews and A Mortensen, Mater Sci Eng A,

Innovative Inorganic Composites Symp., 8-11 Oct 1990 (Detroit, MI), Vol A144, 1991, p 165-168 A new process for infiltrating fibrous preforms with liquid metal that eliminates the need for pressurization of the metal or preform chemical pretreatment is presented The molten matrix material and preform are held in a ceramic crucible so that the melt forms an annulus around the preform The material and preform are then subjected to an intense high frequency magnetic pulse The eddy currents induced in the melt interact with the magnetic pulse to propel the metal into the preform at a high speed, infiltrating the preform The infiltration length is governed by the nature and number of discharges The predicted electromagnetic field

is then used together with Ergun's equation to calculate the infiltration distance

• The Preparation of Oxidation Resistant Silicon Carbide-Silicon Carbide Composites by Chemical Vapor

Infiltration (CVI), D Bashford, New Materials and Their Applications 1990, Proc of the 2nd Int Symp.,

10-12 April 1990 (Warwick, U.K.), D Holland, Ed., IOP Publishing, Bristol, U.K., 1990, p 239-245 Continuous fiber-reinforced ceramics need to be prepared so that they possess benign fracture characteristics to give a good balance between strength and fracture toughness CVI is particularly suitable for preparing SiC-SiC composite shapes, provided specific attention is given to preform construction, fiber

to matrix interfaces, infiltration techniques, and overall composite microstructure

• Processing of Carbon Fiber-Reinforced Aluminum Composite Using K2ZrF6 Treated Carbon Fibers: A

Degradation Study, S.N Patankar, V Gopinathan, and P Ramakrishnan, J Mater Sci Lett., Vol 9 (No 8),

1990, p 912-913 The infiltration of molten aluminum in an array of carbon fibers by application of K2ZrF6onto the fiber surface is discussed The presence of K2ZrF6 causes instantaneous infiltration of carbon fiber torus; however, fiber degradation occurs if the molten aluminum temperature and time of contact during infiltration are not regularly checked

• Microstructural Evolution during the Infiltration Treatment of Titanium Carbide-Iron Composite, K.-W

Chae, D.-I Chun, D.-Y Kim, and Y.-J Baik, J Am Ceram Soc., Vol 73 (No 7), 1990, p 1979-1982 The

microstructural evolution of grain-matrix interfaces in TiC-Fe cermet has been observed and explained in terms of equilibration reaction and interfacial energy minimization The coherency strain energy is assumed

to be the driving force for enhanced dissolution of certain specific planes, which results in a very irregular grain shape The equilibrium shape appears after heat treatment for a long period of time

• Synthesis of SiC Platelet Reinforced 2014 Aluminum Alloys by a Pressure Infiltration Technique, R

Asthana and P.K Rohatgi, J Mater Sci Lett., Vol 10 (No 4), 1991, p 230-234 A technique that employs

countergravity pressure is used to infiltrate prepacked columns of SiC platelets This liquid metallurgy technique is applicable to synthesize aluminum alloy composites containing relatively high (50% or more) volume fractions of platelet-shaped silicon carbide reinforcement

• Fabrication of Cast Particle Reinforced Metals via Pressure Infiltration, E.M Klier, A Mortensen, J.A

Cornies, and M.C Flemings, J Mater Sci., Vol 26 (No 9), 1991, p 2519-2526 A new casting process for

fabrication of particle-reinforced metals whereby a composite of particulate reinforcing phase in metal is first produced by pressure infiltration is presented This composite is then diluted in additional molten metal

to obtain the desired reinforcement volume fraction and metal composition This process produces a free as-cast particulate metal matrix composite It was demonstrated for Mg-SiC particles (3, 10, 30 m) and compared to compocasting (which produces unacceptable porosity)

pore-• Vapor-Phase Fabrication and Properties of Continuous-Filament Ceramic Composites, T.M Besmann,

B.W Sheldon, R.A Lowden, and D.P Stinton, Science, Vol 253 (No 5024), 1991, p 1104-1109 The

continuous-filament ceramic composite is becoming recognized as necessary for new high-temperature structural applications Yet because the filaments are susceptible to damage from traditional methods for the preparation of ceramics, vapor-phase infiltration has become the fabrication method of choice The chemical vapor infiltration methods for producing these composites are now being studied in earnest, with the complexity of filament weaves and deposition chemistry being merged with standard heat and mass- transport relationships Two of the most influential effects on the mechanical properties of these materials are adhesion and frictional force between the fibers and the matrix, which can be controlled by a tailored interface coating A variety of materials are available for producing these composites, including carbide, nitride, boride, and oxide filaments and matrices SiC-based materials are by far the most advanced and are already being used in aerospace applications

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• Chemical Vapor Infiltration (CVI) of Silicon Carbide Fiber Preforms, R Lundberg, L Pejryd, and G Loof,

J Phys (France) IV, Vol 1 (No C2), 1991, p 491-495 An alternative fabrication technique for ceramic

matrix/ ceramic fiber composites involving filling a fiber fabric preform with an Si/Si3N4 slurry and subsequent reaction bonding is presented For the first processing step, chemical vapor deposition (CVD) is evaluated as a means of both binding together and protecting the fibers SiC (Nicalon) fiber preforms consisting of through-stitched two-dimensional fabrics are infiltrated The preform thickness is more than 4

mm, and a 3 m TiC/TiN layer is subsequently deposited on all the fibers, even in the center of the preform after less than 8 h The purpose of the CVI layer is not only to bind the fibers together but also to protect the fiber/matrix interfacial carbon film from reaction with the subsequently infiltrated matrix The remaining porosity of the preform is filled with a Si/Si3N4 powder slurry, which is nitrided to form a reaction bonded

Si3N4 (RBSN) matrix The advantage of this combined CVI/RBSN route is a substantial cut in processing time compared to a process where most of the porosity is filled using CVI

• The Fabrication of Metal Matrix Composites by a Pressureless Infiltration Technique, M.K Aghajanian,

M.A Rocazella, J.T Burke, and S.D Keck, J Mater Sci., Vol 26 (No 2), 1991, p 447-454 A novel

technique for fabricating metal matrix composites by the spontaneous (pressureless) infiltration of filter preforms with molten aluminum alloys is described Numerous reinforcing materials, including Al2O3 and SiC of various configurations, such as particles, agglomerates, and fibers, have been incorporated as fillers The effects of processing variables, such as alloy chemistry, process temperature, and filler material, on the infiltration kinetics and resultant microstructures are discussed Comparisons with existing infiltration technology and preliminary composite properties are presented

• High Pressure Infiltration Casting: Manufacturing Net Shape Composites with a Unique Interface, R.B

Bhagat, Mater Sci Eng A, Vol 144, 1991, p 243-251 An overview of the major casting-based

manufacturing techniques of metal matrix composites is presented (compocasting or rheocasting, squeeze casting, infiltration, investment casting, and pressure casting or squeeze infiltration casting) Attention is focused on high pressure infiltration casting, which uses a rapid application of a relatively high pressure to force-infiltrate molten metal into fiber preforms Reaction between fiber and matrix metal is negligible, and the cast composites are free from voids, gas porosity, and shrinkage cavities

• Pressure Infiltration Casting of Metal Matrix Composites, A.J Cook and P.S Werner, Mater Sci Eng A,

Vol 144, 1991, p 189-206 In pressure infiltration casting, a pressurized inert gas forces the liquid metal into a preform of reinforcement material The method utilizes an enclosed die chamber with controlled pressurization that makes possible the use of low-strength molds with high infiltration pressures This is an inexpensive method to produce composite materials, prototypes, and near-net shapes The parts can be infiltrated and directionally solidified

• Combustion Synthesis of Ceramic-Metal Composite Materials: the TiC-Al2O3-Al System, H.J Feng, J.J

Moore, and D.G Wirth, Metall Trans A, Vol 23 (No 9), 1992, p 2373-2379 One of the main

disadvantages of combustion synthesis of ceramic and composite materials is the relatively high levels of porosity ( 50%) present in the product The article discusses a novel application of combustion synthesis for producing ceramic-metal composites with reduced levels of porosity by allowing an excess amount of liquid metal, generated by the exothermic reaction, to infiltrate the pores This application of combustion synthesis of ceramic-metal composite materials is discussed with respect to a model reaction system that utilizes an inexpensive oxide, i.e., TiO2, reacted with carbon and an excess stoichiometric amount of aluminum The aluminum is in the liquid state at the ignition temperature and is intentionally allowed to infiltrate the porous ceramic matrix (i.e., TiC-Al2O3) produced from the combustion synthesis reaction This in situ process for producing ceramic-metal composites by the simultaneous liquid-metal infiltration of the pores in a ceramic matrix using the combustion synthesis approach provides considerable advantages over a conventional process

• Observations on Infiltration of Silicon Carbide Compacts with an Aluminum Alloy, R Asthana and P.K

Rohatgi, J Mater Sci Lett., 1 Oct 1992, Vol 11 (No 19), 1992, p 1278-1281 The infiltration process

consists of countergravity infiltration of suitably tamped and preheated compacts of SiC platelets under an external pressure in a special pressure chamber for a set period, followed by solidification of the infiltrant metal in the interstices of the bed at atmospheric pressure Some experimental observations are presented

on the infiltration behavior and matrix microstructures that form when porous compacts of platelet-shaped single crystals of -SiC (hexagonal) are infiltrated under gas pressure with a liquid 2014 aluminum alloy

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(nominal composition Al-4.5Cu-0.8Si-0.8Mn-0.5Mg)

• Consolidation of Continuous Fiber Intermetallic-Matrix Composites, S.L Semiatin, R.L Goetz, and W.R

Kerr, Intermetallic-Matrix Composites II Symp., 27-30 April 1992 (San Fransisco, CA), D.B Miracle, D.L

Anton, and J.A Graves, Ed., Materials Research Society, 1992, p 351-364 Processing routes for fabrication of continuous fiber, intermetallic-matrix composites, including conventional and hot isostatic pressing of layups of matrix material (e.g., foil or powder cloth) and fiber mats, consolidation of monotapes made by techniques such as arc, plasma, vapor, or electron beam deposition or tape casting, and liquid- metal infiltration-base methods are reviewed The advantages and disadvantages of the various methods are discussed

• Preparation and Properties of Reinforced Mg-Li Superlight Alloys by High Pressure Infiltration in an

Autoclave, A Schweighofer, E Hornbogen, S Kudela, and K Schemme, Magnesium Alloys and Their Applications, 8-10 April 1992 (Garmisch Partenkirchen, Germany), B.L Mordike and F Hehmann, Ed.,

DGM, 1992, p 423-430 A high pressure infiltration method is used for the production of Mg-Li matrix composites Most favorable materials are magnesium-lithium alloys with up to 8 wt% Li combined with coated carbon fibers Other ceramic fibers such as SiC and Al2O3 are also suitable but raise the bulk density much more than carbon fibers

• Near-Net Shape Long Fiber-Reinforced Intermetallic-Matrix Composites Produced by Reactive Infiltration

Process, H Chen, M Kaya, and R.W Smith, Ed., Mater Lett., Vol 13 (No 4-5), 1992, p 180-183 A

reactive melt infiltration technique is utilized for the processing of intermetallic (NiAl and Ni3Al) matrix composites The intermetallic compound matrix can be formed by in situ reaction during the flow of molten metal or alloy into a nickel-powder preform containing reinforcements With this method, the macrosegregation of nickel can be controlled to produce materials with varying microstructural zones, which can enhance high-temperature mechanical properties

• Discussion of a Liquid-Metal Pressure Infiltration Process to Produce Metal Matrix Composites (MMCs),

J.T Blucher, J Mater Process Technol., Vol 30 (No 3), 1992, p 3821-3900 The two major processing

techniques to manufacture MMCs are solid state diffusion bonding and squeeze casting The former has size limitations; it is suitable for flat sheets or plates, and the manufacturing rate is low and expensive The latter, although suitable for large production of complex shapes, requires heavy and expensive tooling The described pressure infiltration process was developed at the Massachusetts Institute of Technology In this process, fiber, whisker, or particulate preforms are placed in inexpensive disposable containers, into which gas pressure forces the molten matrix material The gas pressure quasi-isostatic, thus reducing the strength requirements for containers and making the process inexpensive As the processing parameters, such as preform and melt temperatures, infiltration pressure, and cooling rate, can be accurately controlled, the process is particularly suitable for research and limited production

• An Advanced Melt Infiltration Process for Net Shape Production of Metal Matrix Composites, O Ottinger

and R.F Singer, Z Metallkd., Vol 84 (No 12), 1993, p 827-831 An alternate process to squeeze casting to

produce fiber-reinforced light metals for the automotive industry is proposed This new process is expected

to have advantages in certain cases, such as low volume production, intricate shapes, and low heat capacity metals First results for the magnesium alloy MSR reinforced with 20 vol% Saffil short fiber are presented, indicating that mechanical properties are equivalent to composites obtained by squeeze casting

• Graded Compositions and Microstructures by Infiltration Processing, B.R Marple and D.J Green, J Mater Sci., Vol 28, 1993, p 4637-4643 Mullite/alumina particulate composites are fabricated by

infiltrating porous alumina preforms with an SiO2-containing sol, followed by a heating step for mullite formation and densification Electron microprobe analysis is performed to obtain concentration profiles across sections of the sintered composites These profiles indicate concentration gradients with mullite content decreasing with increasing distance from the surface of the bodies An increase of the alumina grain size is also noticed in the same direction These two effects (microstructural and compositional) have been related, and it has been concluded that while the mullite presence limits grain growth in alumina, the mullite content has to be at least 5 wt% in order for grain growth to occur in a controlled fashion

• Processing of Molybdenum Disilicide Using a New Reactive Vapor Infiltration Technique, N Patibandla

and W.B Hillig, J Am Ceram Soc., Vol 76, 1993, p 1630-1634 In this new process, a loosely compacted

molybdenum powder is exposed to a gaseous silicon precursor Initially, a surface MoSi2 layer forms that

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subsequently progresses inward At 1200 °C, the silicide layer grows at a rate of about 20 m/h No excess silicon or molybdenum is present, unlike in chemically vapor deposited MoSi2 Irrespective of the volumetric increases involved in siliciding molybdenum to MoSi2, none of the samples silicided between

1100 and 1300 °C showed swelling or surface cracks

• Reactive Melt Infiltration of Silicon-Niobium Alloys in Microporous Carbon, M Singh and D.R Behrendt,

J Mater Sci., Vol 9 (No 7), 1994, p 1701-1708 Reactive melt infiltration of silicon-niobium alloys in

microporous carbon preforms prepared by the pyrolysis of a polymer precursor is studied by modeling, differential thermal analysis (DTA), and melt infiltration experiments Mercury porosimetry results indicate

a very narrow pore size distribution with all open pores The morphology of the residual phases (NbSi2 and Si) in the infiltrated material can be tailored by the control of pore size and distribution of the carbon preform and alloy composition The average room temperature four-point flexural strength of a reaction formed SiC (made by infiltration of medium pore size preforms with Si-5at%Nb) is 290 ± 40 MPa (42 ± 6 ksi), and the fracture toughness is 3.7 ± 0.3 MPa The flexural strength decreases at high temperature due to relaxation of the residual thermal stresses and the presence of free silicon in the material

• Silicon-Aluminum Network Composites Fabricated by Liquid Metal Infiltration, Y.Y Chen and D.D.L

Chung, J Mater Sci., Vol 29 (No 23), 1994, p 6069-6075 A new method for fabricating interpenetrating

silicon-aluminum network metal matrix composites is presented The method involves infiltration of an aluminum-silicon alloy (Al-12Si-1Mg or Al-30Si-1Mg) liquid into a SiC (50 vol%) preform The silicon particles are partially dissolved by the liquid alloy and contribute to the formation of a silicon network after solidification The composites are metallurgically sound with no porosity The thermal expansion coefficient is low (7.7 × 10-6 at 50-100 °C) with compressive strength up to 580 MPa, tensile strength up to

160 MPa, and Vickers hardness up to 390

• Application of Ultrasonic Vibration to Molten Aluminum Infiltration, Y Tsunekawa, H Nakanishi, M

Okumiya, and N Mohri, Key Eng Mater., Vol 104-107, 1995, p 215-224 A new method of infiltration at a

very low applied pressure has been developed Ultrasonic vibration has been applied to improve the wettability of Al2O3 particle or fibers by molten aluminum This ultrasonic vibration allows infiltration to take place at a very low pressure At the same time, noninfiltrated defects are minimized The method has been successfully applied for the fabrication of in situ metal matrix composites starting with titanium powders and Al2O3

• Development of the Technique of Extrusion Directly Following Infiltration for the Manufacturing of

Metal-Matrix Composites, L.X Hu, S.J Luo, W.C Huo, and Z.R Wang, J Mater Process Technol., Vol 49,

1995, p 287-294 A new technique that involves extrusion directly after infiltration is aimed at providing a good bond between the matrix and the reinforcement and eliminating the voids The new method combines melt infiltration, squeeze casting, and semi-solid extrusion and is particularly suitable for the manufacturing

of bars, pipes, plates of fiber, or particulate MMCs

• Reactive Melt Infiltration of Silicon-Molybdenum Alloys into Microporous Carbon Preforms, M Singh and

D.R Behrendt, Mater Sci Eng A, Vol 194 (No 2), 1995, p 193-200 Reactive melt infiltration of

Si-1.7at%Mo and Si-3.2at%Mo alloys into microporous carbon preform is studied by modeling, differential thermal analysis (DTA), and melt infiltration experiments These results indicate that pore volume fraction

of the carbon preform is an important parameter for the final composition of the reaction formed SiC and secondary phases The liquid silicon-carbon reaction exotherm temperatures are influenced by pore and carbon particle size and the compositions of infiltrants Room temperature flexural strength and fracture toughness of Si-3.2at%Mo alloy infiltrated into medium ore size preforms are presented Various undesirable results (e.g., choking-off, specimen cracking, silicon veins, and lake formation) are presented in relationship to inadequate preform properties

• Fabrication of Intermetallic Compound Matrix Composite by Spontaneous Infiltration and Subsequent In

Situ Reaction Process, T Choh, T Mohri, and M Kobashi, J Mater Process Technol., Vol 63 (No 1-3),

1997, p 379-383 Titanium aluminides intermetallic compound matrix composites were in situ synthesized

by spontaneous infiltration of liquid aluminum into a powder mixture of titanium and Al2O3

• Fabrication of Al2O3 Composites by Reactive Melt Infiltration, W.P Tai, Am Ceram Soc., Vol 76 (No 4),

April 1997, p 86-89 Near-net shape Al2O3 composites containing a small amount of silicon metal are fabricated by infiltrating aluminum into Al2O3 particle preforms with the aid of borosilicate glass The

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process is conducted under oxygen atmosphere at ambient pressure (1 atm) using a conventional furnace The growth rate and mechanical properties of the composites are investigated by changing the processing factors

Infiltration Systems

• Wetting and Infiltration of Porous Tungsten and Molybdenum by Liquid Gallium, A.V Ivanov, T.S

Ivanova, L.I Kostenetskaya, Y.I Smirnov, and M.M Churakov, Sov Powder Metall Met Ceram., Vol 23

(No 56-58), 1984 Electrical contacts with a solid skeleton of tungsten or molybdenum have been produced

by liquid gallium infiltration Specimens are compacted under a pressure of 390 MPa and sintered for 2 h in hydrogen at 1400 and 1200 °C, respectively, with resulting porosities of 38 and 44% Wetting experiments are carried out in helium, hydrogen, or vacuum An intermetallic compound and sintered moldybdenum layers that formed at 600 °C prevented gallium infiltration

• Kinetic Laws for Infiltration of Porous Titanium by Lead and Indium Melts, A.A Kurilko, G.A Kurshev,

V.A Rudyuk, and Y.V Naidich, Sov Powder Metall Met Ceram., Vol 23, 1984, p 686-689 This process

is similar to active soldering of nonmetallic oxide materials A molten solder (e.g., tin, lead, or indium) infiltrates and spreads over its surface The work is aimed at studying the kinetics of infiltration of titanium powders by two metallic melts: indium and lead

Metal Matrix Composites (MMC)

• Casting Particulate and Fibrous Metal Matrix Composites by Vacuum Infiltration of a Liquid Metal Under

an Inert Gas Pressure, J Yang and D.D.L Chung, J Mater Sci., Vol 24 (No 10), 1989, p 3605-3612

MMCs are fabricated by a combination of three techniques: vacuum infiltration, infiltration under an inert gas pressure, and squeeze casting The particulate or fiber preform is placed in a mold with the matrix alloy above the preform A gas under pressure (7 to 17.3 MPa or 1000 to 2500 psi) forces the melt to infiltrate the preform The temperature and pressure are below those used in squeeze casting, thus minimizing the interfacial reactions The method has been used to fabricate aluminum-matrix composites with short ceramic

or continuous ceramic fibers (e.g., SiC whiskers) and particle reinforcements (e.g., SiC, Al2O3, graphite flakes)

• Infiltration of Aluminum into Silicon Carbide Compacts, P.B Maxwell, G.P Martins, D.L Olson, and G.R

Edwards, Metall Trans B, Vol 21, 1990, p 475-485 Although liquid-metal processing of MMCs offers

economic advantages, problems related to the nonwetting nature of the ceramic discontinuous reinforcement create obstacles to its ready implementation Infiltration can occur only if a threshold pressure is applied to overcome the unfavorable interfacial forces in the system Experiments were carried out to infiltrate SiC compacts with pure aluminum, Al-1wt%Mg and Al-1wt%Si An incubation time was found to be necessary before infiltration can proceed, even though the threshold pressure is exceeded It is suggested that the mechanism responsible for the incubation phenomenon might be related to a surface modification produced

by either reaction of liquid aluminum with an oxide film on the surface of the particles or coverage of the surface by a capillarity-induced aluminum condensate

• Ceramic Metal Composite Produced by Melt Infiltration, C Toy and W.D Scott, J Am Ceram Soc., Vol

73 (No 1), 1990, p 97-101 A new ceramic-metal composite with continuous interconnected phases is fabricated from sintered AlN infiltrated with aluminum metal A dense, lightweight, hard material with high strength is obtained Advance of the infiltration front is linear with time The activation energy for the process is high (330 kJ/mol) suggesting a chemical reaction rather than viscous flow as the rate controlling mechanism The infiltration rate is inversely proportional to the pore size The thermal and mechanical properties of the composite are promising

• Interface Studies in Cast Fiber-Reinforced Metals, V.D Scott and Y Ming, Advanced Structural Inorganic Composites, Proc of the Satellite Symp 2 on Advanced Structural Inorganic Composites of the 7th Int Meeting on Modern Ceramics Technologies, 27-30 June 1990 (Montecatini Terme, Italy), P Vincenzini,

Ed., Elsevier, 1991, p 95-108 The microstructures of a number of composite materials manufactured by liquid-metal infiltration of a fiber preform are described, with particular reference to the fiber/matrix interface Examples are given whereby the interface is related to the type of bond developed (i.e., physical

or chemical) The complexities introduced by the presence of matrix second phases, including impurities, are mentioned The results, as well as demonstrating the importance of carrying out full and detailed

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microstructural studies of the fiber/matrix interface, emphasize the need to explore and to assess every aspect of composite structure

• Directed Metal Oxidation and Pressureless Metal Infiltration: New Technologies for the Fabrication of

Reinforced Ceramics and Metals, C.R Kennedy, Advanced Structural Inorganic Composites, Proc of the Satellite Symp 2 on Advanced Structural Inorganic Composites of the 7th Int Meeting on Modern Ceramics Technologies, 27-30 June 1990 (Montecatini Terme, Italy), P Vincenzini, Ed., Elsevier, 1991, p 691-700

Key features and advantages of new technologies for fabricating reinforced ceramics and metals are reviewed Microstructures and properties of composites tailored for a variety of applications are presented

• Magnesium-Base Hybrid Composites Prepared by Liquid Infiltration, J Schroeder and K.J Kainer, Mater Sci Eng A, Vol 135 (No 1-2), 1991, p 33-36 Liquid infiltration of ceramic fiber preforms is an economical

alternative to produce magnesium matrix composites with discontinuous fibers The high cost stems from the preform and reinforcements (short fibers or whiskers)

• Two-Dimensional SiC/SiC Composites Processed According to the Isobaric-Isothermal Chemical Vapor

Infiltration Gas Phase Route, R Naslain,J Alloy Compd., Vol 188, 1992, p 42-48 Chemical vapor

infiltration (CVI) is a process according to which a ceramic material is deposited from a gaseous precursor

in the open pores of a heated substrate It has been used to elaborate ceramic matrix composites, starting from porous fiber preforms SiC/SiC composites consist of an SiC CVI-matrix reinforced with Si-C-O expolycarbosilane yarn fibers These composites exhibit nonbrittle mechanical behavior in tension loading when a thin layer of compliant interphase material (turbostratic pyrocarbon or hexagonal boron nitride) with

a low shear failure stress is deposited onto the fibers prior to infiltration of the SiC-matrix When exposed to oxidizing atmospheres, SiC/C/SiC composites are selfhealing if their carbon-interphase is thin enough and the temperature is high Their oxidation resistance can be improved by replacing the vulnerable carbon- interphase by a BN-interphase (low temperature exposures) and/ or adding a glass-former coating on the external surface of the composites

• Effect of Pore Size on the Infiltration Kinetics of Aluminum in Titanium Carbide Preforms, D Muscat, R.L

Harris, and R.A Drew, Acta Metall Mater., Vol 42, 1994, p 4155-4163 Infiltration by capillarity is a

simple and attractive way of fabrication metal/ceramic composites Four different TiC preforms of approximately 58% density with different pore sizes ranging from 1 to 30 m are produced They are suspended in a thermogravimetric analyzer (TGA) and infiltrated with molten aluminum under flowing argon Infiltration profiles are obtained by continuously monitoring the weight change of the preform at temperatures from 860 to 1300 °C Kinetic analysis of the infiltration profiles yields activation energies ranging from 105 to 450 kJ/mol, depending on pore size It is suggested that the driving mechanism changes from a diffusion controlled process for smaller pore size to one that is driven by a surface reaction at the interface of larger pores

• Reactive Infiltration Processing of SiC-Metal and SiC-Intermetallic Composite, L Hozer and Y.M Chiang,

J Mater Res., Vol 11 (No 9), 1996, p 2346-2357 Reactive infiltration is used to infiltrate carbon with

silicon-aluminum and silicon-copper melts to prepare composites consisting of interpenetrating networks of -SiC and a secondary phase assemblage containing ductile metal (silicon-aluminum) or a metal silicide (silicon-copper) The mechanisms of phase formation are characterized A rapid initial reaction upon infiltration forms a largely stationary SiC network, within which the secondary phase evolves due to solute rejection and liquid phase diffusion processes Both homogeneous composites and controlled composition gradients are synthesized

• Fabrication and Analysis of an In Situ TiB2Al Composite by Reactive Spontaneous Infiltration, M Kobashi

and T Choh, Scr Mater., Vol 34 (No 8), April 1996, p 1257-1265 An in situ reactive spontaneous

infiltration is used to fabricate an Al-MgTiB2, AlN composite using TiN, TiCxNx-1, boron powders and aluminum-magnesium ingot as starting materials An experimental setup is also employed in order to study the infiltration process by using a precision multirecorder, which continuously monitors the temperature change in the powder mixture of TiN or TiCxNx-1 and B as the metal infiltrated

Particulate MMC

• The Structure and Properties of Infiltrated Titanium Carbide Cemented Carbide, R.F Mamleev and V.N

Antsiferov, Sov Powder Metall Met Ceram., Vol 29 (No 2), 1990, p 153-156 The influence of the

titanium carbide skeleton porosity and its temperature of infiltration with a multialloyed (9.5% Co, 9.5 Cr,

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2.0 Mo, 10.0 W, 2.6 Ti, 5.4 Al, 0.3% Si) nickel alloy (SNS) on the structure and mechanical properties of the composite created at temperatures up to 1150 °C was studied TiC powder to TU 6-09-492-75 with an average grain size of 3 to 4 m and individual aggregates up to 20 m is used to produce the skeletons The powder is pressed with additions of 5% plasticizer under a pressure of 10 to 400 MPa and sintered in vacuum with a residual pressure of less than 10-2 Pa at 1400 to 1800 °C for 0.5 h The infiltration is done by application of the metal to the skeleton in vacuum at 1450 to 1600 °C for 0.5 h The yield strength in compression is established and the bend strength is determined by the three-point bend method

• Pressureless Sintering of SiC-Whisker-Reinforced Al2O3 Composites II: Effects of Sintering Additives and

Green Body Infiltration, H.-W Lee and M.D Sacks, J Am Ceram Soc., Vol 73 (No 7), 1990, p

1894-1900 Pressureless sintering of SiC-whisker-reinforced Al/Al2O3 composites is investigated The effects of

Y2O3/MgO sintering additives and green body infiltration on the densification behavior and microstructure development are reported Both sintering additives and green body infiltration result in enhanced densification However, the infiltration approach is more effective for samples with high SiC whisker concentrations Samples with 27 vol% whiskers could be pressureless sintered to approximately 93% relative density and approximately 3% open porosity Fracture toughness values and microstructural features (e.g., grain size) for the infiltrated samples remained approximately the same as observed in the uninfiltrated samples

• Squeeze Infiltration A Potential Process to Develop Aluminum Ceramics Particulate Composites, R.S

Solanki, A.K Sing, K Basu, and C.B Raju, Advanced Structural Inorganic Composites, Proc of the Satellite Symp 2 on Advanced Structural Inorganic Composites of the 7th Int Meeting on Modern Ceramics Technologies, 27-30 June 1990 (Montecatini Terme, Italy), P Vincenzini, Elsevier, 1991, p 747-756 All

recent effort on metal matrix composites (MMCs) has considered the light metal, especially aluminum matrix composites (AMCs) The present investigation deals with the development of aluminum ceramic particulate composite using a low cost squeeze infiltration process The defect-free AMCs were produced by

a squeeze infiltration of suitably treated ceramic particulate porous preform by application of pressure up to

150 MPa These AMCs were characterized by optical and scanning electron microscopes Improvement in hardness value over AMCs produced by the Vortex method was observed

• Properties of TaC-Based Metal-Matrix Composites Produced by Melt Infiltration, K Shanker, L.T

Mavropoulos, R.A.L Drew, and P.G Tsantrizos, Composites, Vol 23 (No 1), 1992, p 47-53

TaC/metal-matrix composites were developed for use as electrodes in plasma systems; in addition, they were observed

to possess excellent mechanical properties Composites of TaC/Al, formed by infiltrating TaC preforms with pure aluminum under optimal infiltration conditions of 1500 °C for 0.5 h, had yield strengths of approximately 100 to 125 MPa, ultimate tensile strengths of approximately 440 MPa, and elongations of 7% while containing 48 to 63% TaC The composite consists of discrete TaC particles in a continuous aluminum matrix Increasing the metal infiltration temperature results in a rapid decrease in the tensile properties of these composites Composites of TaC/Cu were not as easy to fabricate as those of TaC/Al Infiltration without distortion or cracking was feasible over a narrow TaC range (43 to 50%) and required the infiltration

to be carried out in vacuum Under these conditions, the composites had a yield strength of 90 to 135 MPa, ultimate tensile strength of approximately 760 MPa, and elongation of approximately 15.3% All the composites had excellent machinability and could be machined using conventional methods and equipment

• Al/TiC Composites Produced by Melt Infiltration, D Muscat, K Shanker, and R.A.L Drew, Mater Sci Technol., Vol 8 (No 11), 1992, p 971-976 An Al/TiC composite has been developed using a melt

infiltration technique Green preforms of TiC were partially sintered to densities ranging from 50 to 85% They were then infiltrated with molten aluminum in argon at atmospheric pressure at temperatures ranging from 950 to 1350 °C The variations in mechanical properties of this composite material with ceramic content and fabrication conditions are presented and the resulting microstructures are discussed The composite exhibited excellent tensile strength values of approximately 475 MN/m2 and up to 5% elongation Fracture behavior mechanisms are also described in relation to the stress-strain curves High infiltration temperatures were found to be detrimental to the mechanical properties because the TiC particle network, which formed during sintering, was broken down by the metallic phase

• Melt Infiltration of Silicon Carbide Compacts, R Asthana and P.K Rohatgi, Z Metallkd., Vol 83 (No 12),

1992, p 887-892 Countergravity, pressure-assisted infiltration with a 2014 aluminum alloy of suitably tamped porous compacts of platelet-shaped single crystals of (hexagonal) SiC was used to measure

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particulate wettability and infiltration kinetics under dynamic conditions relevant to pressure casting of

composites A threshold pressure (pth) for ingression of the infiltrant was identified based on the experimental penetration length versus pressure profiles for a range of experimental variables that include infiltration pressure, infiltration time, SiC size, and SiC surface chemistry (plain, copper coated, and nickel

coated) The results showed that pth decreased whereas the penetration length increased with increasing SiC

size and infiltration time Copper coated SiC led to lower pth (and lower estimated wetting angles) and larger (60 to 80%) penetration lengths compared to uncoated SiC under identical conditions These observations have been discussed in the light of theoretical models of infiltration and the kinetics of wetting

• Infiltration Processing of Metal-Matrix Composites: A Review, R Asthana, P.K Rohatgi, and S.N Tewari,

Process Adv Mater., Vol 2 (No 1), 1992, p 1-17 An overview of the current understanding of some

fundamental materials phenomena relevant to infiltration processing of metal-matrix composites (MMCs) is presented The fundamental aspects of wettability, chemical reaction-induced interfacial phenomena, capillarity, infiltration kinetics and fluid flow, and structure evolution in infiltrated MMCs are discussed in light of results of recent experimental and theoretical studies on some commercially important MMCs, such

as Al2O3-Al and SiC/Al The lack of a comprehensive theoretical framework suitable for rationalizing observations on processing and microstructural aspects of infiltrated MMCs is emphasized and potential areas for further research effort have been identified

• Threshold Pressure for Infiltration in Mica-Ceramic Particle/Aluminum Composite, H Nakanishi, Y

Tsunekawa, M Okumiya, M Higashi, and M Kanatani, J Jpn Inst Light Met., Vol 42 (No 2), 1992, p

92-97 Threshold pressure method was used to evaluate wettability of mica-ceramic particles by molten aluminum Three ceramic particle sizes were used (L, M, S) Pressure infiltration of the particle preforms were performed at 998 K in vacuum and air The threshold pressures were found to be 80.9 (L), 77.8 (M), and 159 (S) in vacuum and 96.9 (L), 96.1, (M) and 162 (S) kPa in air The lower threshold pressure in vacuum is attributed to the better wettability Noninfiltrated defects with a meniscus configuration were observed in the vicinity of two-particle contact Flat defects were noticed in L preforms and aggregate defects in S preforms Modeling of defects with meniscus configuration has been performed, and a contact angle between mica-ceramic and molten aluminum of 2.39 rad was calculated The relationship between the threshold pressure and contact angle is dependent on defect configuration

• Diamond/Aluminum Metal Matrix Composites Formed by Pressureless Metal Infiltration Process, W.B

Johnson and B Sonuparlak, J Mater Res., Vol 8 (No 5), 1993, p 1169-1173 The diamond particles were

coated with SiC prior to pressureless infiltration to prevent the formation of Al4C3 compound The measured thermal conductivity of the initial diamond-aluminum composite is as high as 259 W/m · K The effects of coating thickness on the physical properties of the composite, including Young's modulus, 4-point bend strength, coefficient of thermal expansion, and thermal conductivity, are presented

• Sintering by Infiltration of Loose Mixtures of Powders: a Method for Metal Matrix Composite Elaboration,

V Constantinescu, R Orban, and H Colan, J Phys., Vol 3 (No.7), 1993, p 1781-1786 A comparison

between infiltration of loose powder mixtures and the classical melt infiltration is carried out Factors that prevent excessive hydrostatic flow of the melt and, consequently, dispersion of the reinforcing particles and that promote wettability in both infiltration and liquid phase sintering were identified Results for fusion tungsten carbide and diamond reinforced metal matrix composite are presented

• Effect of Ceramic Particle Size, Melt Superheat, Impurities, and Alloy Conditions on Threshold Pressure for Infiltration of SiC Powder Compacts by Aluminum-Based Melts, S.Y Chong, H.V Atkinson, and H Jones,

Mater Sci Eng A, Vol 173 (No 1-2), 1993, p 233-237 An instrument heated pressure vessel was used to

determine the effect of some experimental variables on the pressurized infiltration of SiC powder preforms

by a series of aluminum-base melts Threshold pressure for infiltration of 2014 aluminum alloy decreased with increasing SiC particle size and increasing melt superheating Impurities in pure aluminum and copper addition (4.2 wt%) to 99.999% pure aluminum increased the threshold pressure, while the addition of an extra 1.0 wt% Mg to 2014 alloy lowered it Superheating the melt reduced the incidence of entrapped porosity in compacts that have a tendency to increase in the infiltration direction Partial SiC dissolution was noted during infiltration

• Zirconia-Alumina Particulate Composites by Infiltration Processing, S Riou, F Queyroux, and P Boch,

Ceram Int., Vol 21 (No 5), 1995, p 339-343 ZrO2/Al2O3 particulate composites were prepared by infiltration of presintered alumina skeletons with a precursor of zirconia and subsequent sintering at 1600

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°C The composite specimens exhibit a gradient in composition; the zirconia content being higher in the superficial zones than in the core The influence of the ZrO2 content on the volume fraction of t-ZrO2, the t

to m transformation temperature, and the microstructural development were studied

• Particulate Composites in the Al2O3-SiO2-TiO2 System by Infiltration Processing, S.J Li, F Queyroux, and

P Boch, J Eur Ceram Soc., Vol 13 (No 1), 1994, p 3-9 Particulate composites in the Al2O3-SiO2-TiO2system were prepared by infiltration of presintered alumina skeletons with precursors of silica and titania and subsequent reaction sintering at temperatures 1600 °C The microstructure of composites is finer than that of the corresponding "pure" alumina It is constituted of alumina grains surrounded by a mullitic, continuous phase

• Fabrication of Particulate Aluminum-Matrix Composites by Liquid Metal Infiltration, S.W Lai and D.D.L

Chung, J Mater Sci, Vol 29 (No 12), 1994, p 3128-3150 The technology was developed to infiltrate high

volume fraction (up to 75%) particulate preforms (AlN, SiC, Al2O3) with molten aluminum A 0.1 wt% acid phosphate binder (with P/Al molar ratio of 23) was used for the preform, in contrast to higher binder amounts necessary for a whisker composite After infiltration by a slurry that consists of the reinforcing particles, binder, and carrier (preferably acetone), a baking at 200 °C was applied for drying Baking in air at

500 °C instead of 200 °C caused oxidation of AlN and subsequent decrease of composite thermal conductivity The binder reinforcement reactivity was larger for AlN than SiC, but it did not affect overall composite properties due to the small amount of binder used The best thermal conductivity and ductility were obtained in Al/AlN, and the poorest were obtained in Al/Al2O3 (due to Al2O3 particle clustering)

• Pressureless Infiltration of Aluminum Metal Matrix Composites, Y Kajikawa, T Nukami, and M.C

Flemings, Met Mater Trans., Vol 26 (No 8), 1995, p 2155-2159 The ceramic preforms are SiC with

varying amounts of particulate aluminum, titanium, and nickel The infiltrants used are aluminum and 12.5%Si It is shown that a pressure differential within the preform is required for infiltration; measurements are made of pressure changes in the preform during infiltration Results indicate that atmospheric pressure is essential for infiltration, but that capillarity can play a role as well

Al-• Synthesis of Composite Materials by Infiltration of lVa, Va Metals and BN Powder Mixtures with Molten

Aluminum, M Kobashi, N Tonokura, and T Choh, J Jpn Inst Light Metals, Vol 46 (No 12), 1996, p

638-643 Ceramic phases were in situ synthesized by the reaction: 2Al + 2BN + Me = MeB2 + 2AlN, where Me is

a metal (Ta, Nb, Zr, or Hf) Each of these metals was mixed with BN powder The spontaneous infiltration occurred with a 3600 s hold at 1473 K Niether pores nor cavities were observed TaB2 and NbB2 were completely formed together with AlN after holding for 3600 s in systems with tantalum and niobium The in situ formed particles were uniformly distributed in the aluminum matrix In systems with zirconium and hafnium, ZrB2 and HfB2, along with BN, were found Differential thermal analysis indicated that the heat of Al-Ta and Al-Nb reactions can ignite a reaction involving BN However, the Al-Zr and Al-Hf reactions that occur at 1000 K do not ignite a reaction with BN Therefore, the processing time was longer for zirconium and hafnium systems The Ta-BN powder mixture was infiltrated with molten aluminum at temperature above 1173 K, and both TaB2 and AlN were found as a result of the in situ reaction

• Fabrication of Metal Matrix Composites (MMCs) by Spontaneous Infiltration and Subsequent In Situ

Reaction Processes, T Choh, M Kobashi, M Nakata, and H Kaneda, Mater Sci Forum, Vol 217-222,

1996, p 353-358 Fabrication of MMCs was developed by applying the in situ reaction followed by spontaneous infiltration of liquid aluminum into a mixture of ceramic and metal powders Next, the spontaneous infiltration of liquid magnesium into SiC powder phase was completed using SiO2 as an infiltration agent in the SiC powder phase

• Precipitation during Infiltration of A201 Aluminum Alloy into Al-Fe-V-Si Preform, C.-C Yang, Y.-C

Chen, and E Chang, Scr Mater., Vol 34 (No 7), 1996, p 1059-1065 A new near-net casting process is

proposed in which liquid aluminum is infiltrated around the Al-Fe-V-Si particles to form a composite material A preliminary study of the Al-Fe-V-Si particle reinforced A201 aluminum alloy demonstrates that the compression strength at 300 °C can be twice as high as A201 aluminum alloy

• Metal Matrix Composites Fabricated by Pressure Assisted Infiltration of Loose Ceramic Powder, M.A Taha

and N.A El-Mahallawy, J Mater Process Technol., Vol 73 (No 1-3), 1998, p 139-146 Pressure was

applied by two methods: centrifugal and squeeze casting The structural features of the composite, including particle distribution, metal/ceramic interface, and part soundness, are shown A comparison of the two

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techniques using a high volume fraction of Al2O3 (50-65%) is made

Metal Matrix Composites (MMC) (Fiber)

• Characterization of Ceramic Matrix Composites Fabricated by Chemical Vapor Infiltration, D.P Stinton,

D.M Hembree, Jr., K.L More, and B.W Sheldon, Chemical Vapor Deposition on Refractory Metals and Ceramics Symp., 29 Nov-1 Dec 1989 (Boston, MA), T.M Besmann and B.M Gallois, Ed., Materials

Research Society, 1990, p 273-280 A process for the preparation of fiber-reinforced SiC composites by chemical vapor deposition has been developed at Oak Ridge National Laboratory Composites are prepared

by infiltrating fibrous preforms with reactant gases that decompose at elevated temperatures to deposit silicon carbide between and around the fibers Because the infiltration process utilizes both temperature and pressure gradients, SiC is deposited under conditions that vary considerably from the hot face to the cool face of the composite Matrix characterization of composite samples by transmission electron microscopy and Raman spectroscopy is described

• Carbon Coated Alumina Fiber/Glass Matrix Composites, R.L Lehman and C.A Doughan, Compos Sci Technol., Vol 37 (No 1-3), 1990, p 149-164 Carbon coated alumina fiber-reinforced borosilicate glass

composites were fabricated by slurry infiltration and hot pressing For fiber contents of 20 vol%, composite strengths of 118 and 263 MPa were observed for uncoated and carbon coated composites, respectively Fiber pull-out was observed in fracture surfaces only for carbon coated composites, and pull-out lengths were approximately 30-60 m The fiber/matrix interface was studied to characterize the interfacial frictional stress Direct measurements by indentation were compared with calculated values based on pull- out lengths and fiber strengths Direct indentation measurements gave interfacial frictional stress values of

100 MPa, which were reduced by as much as 40% after a correction for Poisson's ratio effects Values calculated from pull-out lengths suggested a value of 63-84 MPa, in good agreement with direct measurements Elastic modulus and thermal expansion measurements confirmed the debonded character of the carbon coated fiber/matrix interface

• Fiber-Reinforced Silicon Nitride Composites, R Lundberg, R Pompe, R Carlsson, and P Goursat,

Compos Sci Technol., Vol 37 (No 1-3), 1990, p 165-176 Three possible processing routes to obtain

silicon nitride reinforced with continuous fibers are identified and demonstrated Slip-infiltrated, HIPed carbon fiber-reinforced material, slip-infiltrated, SiC fiber-reinforced nitrided Si3N4, and polysilazane solution infiltrated pyrolysed composites with SiC fibers have been successfully fabricated Possible fiber/matrix reactions are discussed on the basis of scanning electron microscopy observations and the bend fracture behavior of the composites All materials exhibited nonbrittle fracture and are thus potentially interesting composites for further development

• Temperature and Concentration Dependence of SiC Deposition on Nicalon Fibers, T.M Besmann, B.W

Sheldon, and M.D Kaston, Surf Coat Technol., Vol 3-4 (No 1-3), 1990, p 167-175 Chemical vapor

infiltration of Nicalon fiber bundles (approximately 500 filaments) was studied using methyltrichlorosilane

to form the SiC matrix The operating conditions were chosen to simulate those used in composite fabrication It was determined that the deposition reaction has an activation energy of 66 ± 20 kJ/mol and is first order with respect to reactant concentration

• Development of Advanced SiC/Al Composite Material, Manufacturing of Preform Wires by Liquid Metal

Infiltration, Y Imai, Y Tanaka, H Ichikawa, and T Ishikawa, J Iron Steel Inst Jpn., Vol 75 (No 9),

1989, p 1555-1562 The continuous SiC fiber produced by polycarbisilane has outstanding properties as MMC reinforcement SiC/Al (A1050) preform wires were continuously produced by the liquid infiltration method After heating the SiC fiber yarn at 1373 K for desizing, it was dipped into molten aluminum at 953

K and then passed through a ceramic nozzle hole 0.25 mm in diameter The tensile strength of the preform wire is 1560 MPa

• Silicon Carbide/Silicon and Silicon Carbide/Silicon Carbide Composites Produced by Chemical Vapor

Infiltration, M Kmetz and S Suib, J Am Ceram Soc., Vol 73 (No 10), 1990, p 3091-3903 Composites

of SiC/Si and SiC/SiC were prepared from single yarns of SiC The use of carbon coatings on SiC yarn prevented the degradation normally observed when chemically vapor deposited silicon is applied to SiC yarn The strength, however, was not retained when the composite was heated at elevated temperatures in air In contrast, the strength of a SiC/C/SiC composite was not reduced after being heated at elevated temperatures, even when the fiber ends were exposed

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• Influence of Aluminum Alloy Matrices on the Strength of SiCPCS Fiber-Reinforced Preform Wires by

Liquid Metal Infiltration, Y Imai, Y Tanaka, H Ichikawa, and T Ishikawa, J Iron Steel Inst Jpn., Vol 76

(No 1), 1990, p 65-72 The matrices used were aluminum-base binary alloys with 5wt% Si, Cu, and Mg, and commercial A2024, A5052, A6061, and A7075 alloys No wire with high strength was obtained in any matrix Silicon precipitated on the surface of SiC fiber in Al-5Si CuAl2 was observed in Al-CuAl2 eutectic and magnesium-diffused into the fiber in Al-5Mg Similar compounds were found when using industrial alloys An Al-3Cu-2Ni alloy was designed and the fiber-melt contact was shortened The tensile strength of the wire obtained was 1 GPa

• Melt Infiltration and Reaction at the Fiber/Matrix Interface during the Brazing of a Fiber-Reinforced

Ceramic to Metal, S Karunanithy, J Am Ceram Soc., Vol 73 (No 1), 1990, p 178-181 The presence of

silica in the fiber/matrix interface of SiC fiber-reinforced alumina facilitates the brazing of these composites with metals In addition, molten braze infiltrates the interfacial pores to form reaction layers with the matrix and the fiber The chemical compatibility, wetting, and thermodynamics of the titanium- base braze leads to a potentially useful method of joining a fiber-reinforced ceramic to metal

• Chemical Stability of Zirconia-Stabilized Alumina Fibers during Pressure Infiltration by Aluminum, J.A

Isaacs, F Taricco, V.J Michaud, and A Mortensen, Metall Trans A, Vol 22 (No 12), 1991, p 2855-2862

MMCs composed of high purity aluminum and continuous zirconia-stabilized polycrystalline Al2O3 fibers are fabricated by liquid metal infiltration using three different casting procedures The microstructure of the composites showed discrete faceted ZrAl3 particles at the interface that grow into the matrix in samples processed above matrix melting point for more than 13 minutes This compound formation is in agreement with the thermodynamic stability calculations There is also a reaction between solid aluminum and the fibers at 913 K, yielding a reaction product of the same morphology as with molten aluminum When infiltration occurs in a preform heated below the metal melting point and solidification time is less than 1 min, no reaction products are seen in SEM This leads to the conclusion that aluminum MMC can be cast with no apparent interfacial reaction product using these fibers provided that adequate processing parameters are chosen

• Influence of Fiber Array on the Threshold Pressure on Infiltration in Alumina Fiber/Aluminum Composite,

H Nakanishi, Y Tsunekawa, M Okumiya, M Higashi, and I Niimi, J Jpn Inst Light Met., Vol 41 (No

5), 1991, p 325-330 It was shown experimentally that the fiber arrangement greatly influences the threshold pressure of infiltration in the alumina fiber/molten aluminum system The threshold pressure for the unidirectionally fiber array is 425 kPa, a value less than theoretical because of the slight disarray in the fiber alignment By contrast, the experimental value for quasi-planar random array is 245 kPa The relation between the threshold pressure and wettability is derived for infiltration with noninfiltrated defects at the contact of nonwetted two fibers The threshold pressure of alumina fiber/molten aluminum system with defects is less than that without defects, and it decreases with decrease in contact angle of two fibers because of increasing defects

• Influence of Processing Parameters on the Threshold Pressure of Infiltration in Alumina Fiber/Aluminum

Composite System, H Nakanishi, Y Tsunekawa, M Okumiya, and I Niimi, J Jpn Inst Light Met., Vol

41 (No 9), 1991, p 576-581 Although fiber arrangement in the preform does not affect the interfacial energies or contact angles, it affects the processing parameters like pressurizing rate, pressure holding at the maximum pressure applied, wettability, and therefore, threshold pressure In this study, a -

Al2O3/molten aluminum composite was selected to investigate such dependence Pressurizing rate was changed from 0.20 to 16 kPa/s and pressure holding at maximum pressure was 300 s No effect of these parameters on the threshold pressure was observed in Al2O3 preforms with quasi-planar random arrangement Experimentally, it was shown that the threshold pressure obtained by extrapolation of infiltration distance and applied pressure agrees with that obtained from the Blake-Kozeny equation The influence of molten aluminum temperature on the threshold pressure that was obtained by the pressure drop was studied at the pressurizing rate of 2.4 kPa/s The threshold pressure decreases from 259 to 162 kPa when molten aluminum temperature increased from 943 to 1163 K

• Characterization of Metal-Matrix Composites Fabricated by Vacuum Infiltration of a Liquid Metal under

an Inert Gas Pressure, J.-M Chiou and D.D.L Chung, J Mater Sci., Vol 26 (No 10), 1991, p 2583-2589

Silicon carbide whisker-reinforced aluminium was fabricated by vacuum infiltration of liquid aluminum into a porous whisker preform under an argon gas pressure, using an infiltration temperature of 665 °C The

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