Features of combustion synthesis waves for certain typical reactions [3-18] Type of interaction Reaction Experimental combustion temperature, °C Combustion wave velocity, cm/s Solid-s
Trang 2C OMBUSTION S YNTHESIS OF
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This publication is designed to provide accurate and authoritative information with regard to the subject matter covered herein It is sold with the clear understanding that the Publisher is not engaged in rendering legal or any other professional services If legal or any other expert assistance is required, the services of a competent person should be sought FROM A DECLARATION OF PARTICIPANTS JOINTLY ADOPTED BY A COMMITTEE OF THE AMERICAN BAR ASSOCIATION AND A COMMITTEE OF PUBLISHERS
L IBRARY OF C ONGRESS C ATALOGING - IN -P UBLICATION D ATA
1 Self-propagating high-temperature synthesis 2 Refractory
materials Heat treatment 3 Refractory materials Mathematical models
Trang 8To the memory of Professor Zinoviy P Shulman (1924-2007) and Professor Leonid G Voroshnin (1936-2006) who had taught me the scientific meaning of old Russian proverb, “trust, but verify”
The important thing in science is not so much to obtain new facts as to
discover new ways of thinking about them
Sir William Bragg
Trang 10C ONTENTS
Chapter 1 Advances and Challenges in Modeling Combustion
Chapter 2 Modeling Diffusion-Controlled Formation
Chapter 3 Modeling Interaction Kinetics in the CS
Chapter 4 Analysis of the Effect of Mechanical
Trang 12P REFACE
Self-propagating high-temperature synthesis (SHS), or combustion synthesis (CS) is a phenomenon of wave-like localization of chemical reactions in condensed media which permits efficiently synthesizing a wide range of refractory compounds (carbides, borides, intermetallics, etc.) and advanced composite materials CS, where complex heterogeneous reactions proceed in substantially non-isothermal conditions, brings about fine-grained structure and novel properties of the target products and is characterized by fast accomplishment interaction, within ~0.1-1 s, whereas traditional furnace synthesis
of the same compounds in close-to-isothermal conditions may take several hours for the same particle size and close final temperature Uncommon, non-equilibrium phase formation routes inherent of SHS, which have been revealed experimentally, are the main subject of this book
The main goal of this book is to describe basic approaches to modeling isothermal interaction kinetics during CS of advanced materials and reveal the existing controversies and apparent contradictions between different theories, on one hand, and between theory and experimental data, on the other hand, and to develop criteria for a transition from traditional solid-state diffusion-controlled phase formation kinetics (a “slow”, quasi-equilibrium interaction pathway) to non-equilibrium, “fast” dissolution-precipitation route
Trang 13intermetallic compound), in strongly non-isothermal conditions using the diffusion approach and experimentally known values of the diffusion parameters;
• novel criteria for the changeover of interaction routes in these systems and phase-formation mechanism maps;
• analysis of the physicochemical mechanism of the experimentally known strong influence of preliminary mechanical activation of solid reactant particles on SHS in metal-based systems
It is anticipated that the book will serve the scientists, engineers, graduate and post-graduate students in Solid-State Physics and Chemistry, Heterogeneous Combustion, Materials Science and related areas, who are involved in the research and development of CS-related methods for the synthesis of novel advanced materials
Trang 14Chapter 1
1.1 APPROACHES TO MODELING NON-ISOTHERMAL
INTERACTION KINETICS DURING CS
Combustion synthesis (CS), or self-propagating high-temperature synthesis (SHS), also known as solid flame, is a versatile, cost and energy efficient method for producing refractory compounds (carbides, borides, nitrides, intermetallics,
complex oxides etc.) and advanced composite materials possessing fine-grain
structure and superior properties Extensive research in this area was initiated by A.G.Merzhanov in Chernogolovka, Moscow district, Russia, in mid 1960es [1,2], who is internationally recognized as a pioneer of SHS The advantages of CS include short processing time, low energy consumption, high product purity due
to volatilization of impurities, and unique structure and properties of the final products Besides, CS can be combined with pressing, extrusion, casting and other processes to produce near-net-shape articles [3-10] Despite vast literature available in this area, CS is still a subject of extensive experimental and theoretical investigation
Combustion synthesis can be carried out in the wave propagation mode, or
“true SHS”, and in the thermal explosion (TE) mode In the former case, a compact reactive powder mixture is ignited at one end to initiate an exothermic reaction which propagates through the specimen as a combustion wave leaving behind a hot final product [3-10] In the latter case, a pellet is heated up at a prescribed rate (typically 1-100 K/s) until at a certain temperature called the ignition point, Tign, an exothermal reaction becomes self-sustaining and the temperature rises to its final value, TCS, almost uniformly throughout the sample
Trang 15Typically, the value of Tign is close to the melting point of a lower-melting reactant or to the eutectic temperature
Examples of CS products are listed in Table 1.1, and characteristics of SHS reactions in certain systems are presented in Table 1.2
Table 1.1 Examples of compounds and materials produced by combustion
synthesis [3-14]
Type of material Compounds and adiabatic combustion temperature, K (in brackets) Borides TiB 2 (3190), TiB (3350), ZrB 2 (3310), HfB 2 (3320), VB 2 (2670),
VB (2520), NbB 2 (2400), NbB, TaB 2 (2700), TaB, CrB 2 (2470), CrB, MoB 2 (1500), MoB (1800), WB (1700), LaB 6 (2800) Carbides TiC (3210), ZrC (3400), HfC (3900), VC (2400), Nb 2 C (2600),
NbC (2800), Ta 2 C (2600), TaC (2700), SiC (1800), WC, B 4 C,
Cr 3 C 2 , Cr 7 C 3 , Mo 2 C, Al 4 C 3 Aluminides Ni 3 Al, NiAl, Ni 2 Al 3 , TiAl, CoAl, Nb 3 Al, Cu 3 Al, CuAl, FeAl Silicides Ti 5 Si 3 (2500), TiSi (2000), TiSi 2 (1800), Zr 5 Si 3 (2800), ZrSi
(2700), ZrSi 2 (2100), WSi, Cr 5 Si 3 (1700), CrSi 2 (1800), Nb 5 Si 3 (3340), NbSi2 (1900), MoSi2 (1900), V5Si3 (2260), TaSi2 (1800) Intermetallics NbGe, TiCo, NiTi
Sulfides and selenides MgS, MnS (3000), MoS2 (2900), WS2, TiSe2, NbSe2, TaSe2,
MoSe 2 , WSe 2 Hydrides TiH2, ZrH2, NbH2, CsH2
Nitrides TiN (4900), ZrN (4900), VN (3500), HfN, Nb 2 N (2670), NbN
(3500), Ta2N (3000), TaN (3360), Mg3N2 (2900), Si3N4 (4300),
BN (3700), AlN (2900) Carbonitrides TiC-TiN, NbC-NbN, TaC-TaN, ZrC-ZrN
Complex oxides Aluminates (YAlO 2 , MgAl 2 O 4 ), niobates (NaNbO 3 , BaNb 2 O 6 ,
LiNbO 3 ), garnets (Y 3 Al 5 O 12 , Y 3 Fe 5 O 12 ), ferrites (CoFe 2 O 4 , BaFe 2 O 4 , Li 2 Fe 2 O 4 ), titanates (BaTiO 3 , PbTiO 3 ), molybdates (BiMoO 6 , PbMoO 4 ), high-temperature superconductors (YBa 2 Cu 3 O 7-x , LaBa 2 Cu 3 O 7-x , Bi-Sr-Ca-Cu-O) Ternary solid solutions
based on refractory
compounds
TiB 2 -MoB 2 , TiB 2 -CrB 2 , ZrB 2 -CrB 2 , TiC-WC, TiN-ZrN, MoS 2 NbS 2 , WS 2 -NbS 2
-MAX phases Ti2AlC, Ti3AlC2, Ti3SiC2
Cermets Ni, Cr, Co, Ni-Cr, Ni-Mo, Fe-Cr,
TiC-Cr3C2-Ni, TiC-Cr3C2-Ni-Cr, Cr3C2-Ni-Mo, TiB-Ti, WC-Co, TiN-NiAl-Mo 2 C-Cr
Si 3 N 4 -TiN-SiC, sialons (SiAlO x N y )
Trang 16Table 1.2 Features of combustion synthesis waves for certain typical
reactions [3-18]
Type of interaction Reaction Experimental
combustion temperature, °C
Combustion wave velocity, cm/s Solid-solid (formation of
a carbide) via a transient
liquid phase (melting of a
metallic reactant) [17,18]
Ti (solid→liquid) + C (solid) → TiC (solid)
≈2500 3-4
Solid-solid (formation of
a complex oxide) via a
transient liquid phase
with participation of an
oxidizing gas
3Cu (solid→liquid) + 2BaO2 (solid) + (1/2)Y2O3 (solid) + O2(gas) → YBa 2 Cu 3 O 7-x (solid)
→ C 7 H 14 N 2 O 4 (solid, salt)
155 0.06-0.15
The unique features of the obtained products, e.g., high purity, small and
uniform grain size, etc., are ascribed to extreme conditions inherent in CS, which may bring about unusual reaction routes: (i) high temperature, up to 3500 °C, (ii)
a high rate of self-heating, up to 106 K/s, (iii) steep temperature gradient in SHS waves, up to 105 K/cm, (iv) rapid cooling after synthesis, up to 100 K/s, and (v) fast accomplishment of conversion, from about 1 s to the maximum of 10 s [3-6]
It should be noted that traditional furnace synthesis of refractory compounds requires a much longer time, ~1-10 h, for the same initial composition, particle size and close final temperature It has been demonstrated experimentally [16-23] that in many systems phase and structure formation during CS proceeds via uncommon interaction mechanisms from the point of view of the classical Physical Metallurgy [24,25]
Modeling and simulation traditionally play in important part in the development of CS and CS-related technologies (see reviews [3-5,11,26-29] and
Trang 17references cited therein) An adequate mathematical model is supposed to describe both heat transfer in a heterogeneous reactive medium and the interaction kinetics, which is responsible for heat release during CS
In modeling CS, a quasi-homogeneous, or continual model [30,31], which is based on classical combustion theory, is widely used Heat transfer, which is considered on the volume-averaged basis, and the reaction rate in a sample are described as follows:
where T is temperature, ρ is density, cp is heat capacity, λ is thermal conductivity,
Q is the heat release of exothermal reactions, η is the degree of chemical conversion (from 0 in the unreacted state to 1 for complete conversion), R=8.314
Jmol–1K–1 is the universal gas constant, n (the reaction order), k (preexponential factor) and m are formal parameters and E is the activation energy; term Q∂η/∂t denotes the heat release rate
The thermal structure of a combustion wave according to Zeldovich and Frank-Kamenetskiy [32] is shown schematically in Figure 1.1 Typically, three zones are distinguished: (i) the preheating zone where almost no reaction occurs and the main processes are heat and mass transfer accompanied with evaporation
of volatile impurities; in Russian literature it is often termed as “the Michelson zone” after V.A.Michelson (1860-1927) who described the temperature profile ahead of the moving combustion front [32], (ii) zone of thermal reaction where the conversion degree η sharply increases and the heat release rate reaches its maximum and starts decreasing while the temperature almost reaches the adiabatic value, and (iii) the after-burn, or post-reaction zone where the interaction terminates The latter zone is characterized by a slow increase in both conversion degree and temperature, which finally attain their maximal values η=1 and T=Tad, and the heat release rate, Q∂η/∂t, falls down to zero The temperature
of the reaction front, Tf, corresponds to the onset of fast thermal reaction In regard to combustion synthesis of materials, it is believed that complex heterogeneous reactions, which may proceed via uncommon (fast) mechanisms and are responsible for major heat release, occur in the thermal reaction zone while the after-burn zone, where the heat release rate is minor, is dominated by the processes bringing about the formation of final structure of the product, such
as Ostwald ripening, recrystallization etc
Trang 18Figure 1.1 Schematic of the thermal structure of a combustion wave
The approach formulated in Eqs (1.1) and (1.2) permitted modeling dynamic
regimes of SHS, e.g., oscillating [30] and spin combustion [33,34] It was also
used for studying the effect of intrinsic stochasticity of heterogeneous reactions, which can be attributed to a difference in the surface morphology, impurity content and hence reactivity of solid reactant particles, on the dynamic behavior
of a solid flame for a one-stage [35] and multi-stage reaction [36] employing the cellular automata method
It should be outlined that this model is not linked to any process-specific phase formation mechanism and hence is referred to as a formal one When applying this approach to modeling CS in a particular system, the value of the
most important model parameter, viz activation energy E, is supposed to
correspond to the apparent activation energy of the CS as a whole The latter is determined from experimental graphs “the combustion wave velocity vs temperature” plotted in the Arrhenius form, and in its physical meaning corresponds to a real rate-limiting stage of phase formation during CS, which may
be different in different temperature ranges For example, below the melting temperature, Tm, of a metallic reactant E always refers to solid-state diffusion in the product while at T>Tm it can refer to processes in the melt (diffusion or crystallization) [37] This method for choosing the E value was used when studying numerically the conditions of arresting a high-temperature state of substances in the SHS wave by fast cooling for the cases of a one-stage [38] and two-stage exothermal reaction [39]
Trang 19In recent papers [40,41], this formal model [see Eqs (1.1) and (1.2)] was employed for studying the SHS of a NiTi shape memory alloy The activation energy used in calculations was E=113 kJ/kg, which is equivalent to 12.05 kJ/mol (because the molar mass of NiTi is 106.6 g/mol) This is an extraordinary low value for a reaction in a condensed system and can correspond only to diffusion in
a transient melt formed in the CS wave However, according to reference data [42], the activation energy for diffusion in some pure liquid metals is the following: Li, E=12 kJ/mol; Sn, E=11.2 kJ/mol; Zn, E=21.3 kJ/mol; Cu, E=40.7 kJ/mol; Fe, E=51.2 kJ/mol Thus the value of E used for calculations in [40,41] is close to that for diffusion in low-melting metals such as Li or Sn, and is by the factor of 4 lower than for iron whose melting point, Tm, lies between Tm of Ni and
Ti (the activation energy for diffusion in liquid metals is known to be proportional
to Tm [43]) All the more, this E value is incomparably lower than a typical activation energy for diffusion in intermetallic compounds Hence in this case the most important parameter of the formal model, E, appears to be physically meaningless
Recently, new features of SHS were observed experimentally [44-47] First, microscopic high-speed video recording [44,45] and photographing [46] demonstrated micro-heterogeneous nature of SHS which revealed itself in the roughness of the combustion wave front, chaotic oscillations of the local flame propagation rate and new dynamic behaviors such as relay-race, scintillation and quasi-homogeneous patterns Second, the formation of non-equilibrium structure and composition of SHS products was examined experimentally and interpreted qualitatively in terms of relationships between characteristic times of reaction tr, structuring ts and cooling tc [47] These features were attributed to two main factors: inhomogeneous heat transfer in the charge mixture and a specific reaction mechanism [46]
These results gave rise to new, heterogeneous models [48-51] involving heat transfer on the particle-to-particle basis [48-50] and percolation phenomena in a system of chaotically distributed reactive and inert particles [51] However, in these models the traditional formal kinetics for a thermal reaction [Eq (1.2)] was employed Thus, an urgent and still unresolved problem in CS is an adequate description of fast interaction kinetics in a unit reaction cell containing particles or layers of dissimilar reactants whose composition corresponds to the average composition of a charge mixture
The most widely used kinetic model, which is connected to a particular phase forming mechanism, is a “solid-state diffusion-controlled growth” concept first applied to CS in [52] for planar symmetry and in [53] for spherical symmetry of
an elementary diffusion couple As in a charge mixture there are contacts of
Trang 20dissimilar particles, a layer of an intermediate or final solid product forms upon heating thus separating the initial reactants The growth rate of the reaction product and associated heat release necessary for sustaining combustion is controlled by solid-state diffusion through this layer Then, the diffusion-type Stefan problem is formulated instead of Eq (1.2) However, as demonstrated below in more detail, in most cases modeling was performed not with real diffusion data, which are known for many refractory compounds, but using either dimensionless coefficients varied in a certain range or fitting parameters chosen to match the calculated and measured results of the SHS temperature profile and velocity It should be emphasized that Diffusion in Materials is a well-developed cross-disciplinary area within Materials Science and Solid State Physics, and the diffusion parameters for many of the phases produced by CS (carbides, nitrides, intermetallics etc.) have been measured experimentally at different temperatures, and these data are supposed to be used in modeling Besides, in most of the CS-systems fast interaction begins after fusion of a lower-melting-point reactant [3-5,31] but within this approach melting does not alter the phase layer sequence in
an elementary diffusion couple [52,53]
A number of experimental results obtained by the combustion-wave arresting technique in metal-nonmetal (Ti-C [17,18], (Ti+Ni+Mo)-C [19], Mo-Si [20]) and metal-metal (Ni-Al [21,23]) systems gave rise to an qualitative notion of a non-traditional phase formation route It involves dissolution of a higher-melting-point reactant (metal or non-metal) in the melt of a lower-melting-point reactant and crystallization of a final product from the saturated liquid
Besides, there is much controversy over the presence of an intermediate solid phase in the dissolution-precipitation route In [21] it is concluded that during SHS in the Ni-Al system, solid Ni dissolves in liquid Al through a solid interlayer separating aluminum from nickel, which agrees with the phase diagram In this case, the rate-limiting stage is solid-state diffusion across this layer But in [23] for the same system it is found that above 854 °C a solid interlayer between nickel and molten Al is absent; then the overall interaction during CS is controlled by either diffusion in the melt or crystallization kinetics
Such a situation is considered in recent models [54-59], where a solid reactant (nickel [54-56] or carbon [57-59]) dissolves directly in the liquid based on a lower-melting component (Al and Ti, respectively) and product grains (NiAl and TiC, correspondingly) precipitate from the melt; the rate-limiting stage is liquid-phase diffusion [54-56] or crystallization kinetics [57-59] However, within these approaches the fundamental problem of the existence of a thin solid-phase interlayer at the solid/liquid interface is not discussed nor a criterion is obtained for transition between the solid-state diffusion-controlled mechanism and the
Trang 21dissolution-precipitation route with or without a thin interlayer Hence, the applicability limits of the existing modeling approaches have not been clearly determined so far The role of high heating rates, which are intrinsic in CS, in most of the models is not accounted for in an explicit form
Thus, adequate description of the interaction kinetics in condensed heterogeneous systems in non-isothermal conditions of CS is an urgent problem in this area of science and technology, and the absence of a comprehensive model hinders the development of new CS-based processes and novel advanced materials
Hereinafter the situation where a reaction between condensed reactants
proceeds through a solid layer, i.e solid reactant (C for the Ti-C system or Ni for
the Ni-Al system)/solid final or intermediate product (TiC or one of intermetallics
of the Ni-Al system, respectively)/liquid (Ti or Al melt), will be provisionally called “solid-solid-liquid mechanism” since the interaction occurs at both solid/solid and solid/liquid interface This term will be used both for the “solid-state diffusion-controlled growth” pattern where the product layer is growing and for dissolution-precipitation route where the interlayer remains very thin As the diffusion coefficient in a melt is much higher than in solids, the rate-limiting stage
in this mechanism is diffusion across the solid interlayer The second route, viz
dissolution-precipitation without an interlayer, can be referred to as “solid-liquid mechanism” since the interaction of condensed reactants (solid C or Ni with molten Ti or Al, respectively) occurs at the solid/liquid interface while the product (TiC or NiAl) crystallizes from the melt However, up to now the solid-liquid mechanism has not been validated theoretically, nor the applicability limits of the solid-solid-liquid mechanism based on solid-state diffusion kinetics have ever been determined with respect to strongly non-isothermal conditions typical of CS Thus, the main goal of this work is to develop a system of relatively simple estimates and evaluate the applicability limits of the “solid-solid-liquid mechanism” approach to modeling CS and determine criteria for a change of interaction routes basing the calculations on experimental data to a maximum possible extent [60,61] Below, a brief discussion of the diffusion concept of CS is
presented Then, calculations for particulars system, viz Ti-C and Ni-Al, are
performed using available experimental data on both the diffusion coefficients in the growing phase and thermal characteristics of CS
The choice of these binary systems for a modeling study is motivated by the following reasons First, those are typical SHS systems which have been a subject
of extensive experimental investigation (see reviews [3-11,16] and references
cited therein) Second, the synthesis products, viz TiC and NiAl, have a wide
industrial application because of their unique physical and mechanical properties
Trang 22Hence a large number of parameters needed for numerical calculations can be found in literature Third, both of these substances are typical representatives of wide classes of chemical compounds that have different properties connected with their intrinsic structural features Titanium carbide is a typical interstitial compound (like many carbides, nitrides and certain borides) wherein the diffusivities of constituent atoms, Ti and C, differ substantially Hence the growth
of TiC in an elementary diffusion couple Ti/TiC/C during CS is dominated by the diffusion of carbon atoms in the TiC layer and proceeds mainly at the Ti/TiC interface The experimentally measured parameters such as the chemical diffusion coefficient or the parabolic growth-rate constant for TiC are connected with the partial diffusion coefficient of carbon in this compound Nickel monoaluminide is
a typical substitutional compound with an ordered crystalline structure (like many intermetallics) where the rates of diffusion of Ni and Al atoms are comparable Thus its growth during CS occurs at both sides of a NiAl layer and can be characterized by a single parameter, namely the interdiffusion coefficient, which
is measured experimentally
For the Ti-C system, different situations are considered that can arise during
CS within the frame of the above concept and, wherever possible, a quantitative and/or qualitative comparison between the outcome of calculations and experimental results is drawn Emphasis is made on the structural characteristics
of the CS product, titanium carbide, that emerge from this approach The conditions for a change of the geometry of a unit reaction cell in the SHS wave due to melting of a metallic reactant (titanium) are analyzed and a micromechanistic criterion for the changeover of interaction pathways is derived For the Ni-Al system, calculations within the frame of the diffusion-controlled growth kinetics are performed taking into account both the growth of the product phase, NiAl, and its dissolution in the parent phases (solid or liquid Ni and molten Al) due to variation of solubility limits with temperature according to the equilibrium phase diagram Finally, the “solid-liquid mechanism” concept for CS
is justified and phase-formation mechanism maps for these two systems in strongly non-isothermal conditions are plotted
Trang 231.2 BRIEF REVIEW OF DIFFUSION-BASED
KINETIC MODELS OF CS
The interaction kinetics controlled by solid-state diffusion was used for numerical [52,53,62-69] and analytical [70] study of CS for the case of planar diffusion couples (alternating lamellae of reactants) [52,63,64,66,70] and spherical symmetry (growth of a product layer on the surface of a spherical reactant particle) [53,65,67-69]
Inherent in this concept are two basic assumptions: (i) the phase composition
of the diffusion zone between parent phases corresponds to the isothermal
cross-section of an equilibrium phase diagram, i.e the nucleation of product phases
occurs instantaneously over all contact surfaces and (ii) the interfacial concentrations are equal to equilibrium values This results in the parabolic law of phase layer growth [71-73]
It should be noted that in many diffusion experiments the phase layer sequence deviates from equilibrium: the absence of certain phases was observed
in solid-state thin-film interdiffusion [74,75] and in the interaction of a solid and a
liquid metal (e.g., Al) [76,77] These phenomena were ascribed to a reaction
barrier at the interface of contacting phases [78] without considering the nucleation rate of a new phase The effect of a nucleation barrier was examined theoretically using the thermodynamics of nucleation [79,80] and the kinetic mechanism of phase formation in the diffusion zone [81], and it was shown that in the field of a steep concentration gradient the formation of an intermediate phase
is suppressed [79-81] This effect has never been considered in the diffusion models of CS As in the theory of diffusion-controlled interaction in solids the nucleation kinetics is not included and it is assumed that critical nuclei of missing phases continuously form and dissolve [72,73], this qualitative concept is sometimes used in interpreting the results of CS [21]
It will be fair to say that deviation of phase-boundary concentrations from equilibrium due a reaction barrier was examined qualitatively for SHS [64] in the case of planar geometry This effect is noticeable only in the low-temperature part
of the SHS wave, and at high temperatures a strong barrier can only slightly decrease the combustion velocity [64] Also, the influence of such barrier on self-ignition in the Ni-Al system at low heating rates, dT/dt<60 K/min, was studied quantitatively using experimental data on both thin-film interdiffusion in the NiAl3 compound [82], which is the first phase to form in Ni-Al diffusion couples, and bulk diffusion data [83] Similar calculations were performed using an experimental temperature profile of SHS to determine the NiAl3 layer thickness
Trang 24formed below the melting point of aluminum Tm(Al)=660 °C [67] At a thick NiAl3 layer (low heating rates) the reaction barrier is of little significance, but it
can slow down the interaction for thin layers (higher heating rates) [83,67]: e.g., at
dT/dt > 35 K/min the formation of the primary product can be suppressed [67] But, as noted in [83,67], these results refer not to the SHS itself but only to a
preliminary stage (i.e the preheating zone of the SHS wave) because fast
interaction begins at T>Tm(Al), the combustion temperature reaches 1400 °C and the final product is NiAl [67]
It should be outlined that in many works using the diffusion model of CS the calculations were performed with dimensionless (relative) parameters varied in a certain range A known or estimated value of the activation energy for diffusion in one of the phases was used only as a scaling factor and thus the results obtained revealed only qualitative characteristics of the process [52,53,62,66] Besides, many of the modeling attempts [52,53] did not account for a change in the spatial configuration of reacting particles due to melting and spreading of a metallic reactant The effect of melting was reduced to a change of interfacial concentrations and the ratio of diffusion coefficients in contacting phases [62]
In more recent papers [67,68], the parameter values (the activation energy E and preexponent D0) used for calculating the diffusion coefficient in a growing phase were presented However, those were not the real values measured in independent works on solid-state diffusion but merely fitting parameters calculated from the characteristics of CS For example, the formation of NiAl above 640 °C was modeled using D0=4.8×10–2 cm2/s and E=171 kJ/mol [67] As noted in [67], this E value was the experimentally determined activation energy for the CS process as a whole Then the diffusion coefficient in NiAl at T=1273 K
is D = D0exp(−E/RT) = 4.6×10−9 cm2/s Let’s compare it with experimental data
on reaction diffusion in the Ni-Al system For NiAl, D=(2.5–3.6)×10−10 cm2/s at T=1273 K [84] The parameters for interdiffusion in this phase are E=230 kJ/mol and D0=1.5 cm2/s [85], hence at T=1273 K D=5.4×10−10 cm2/s Thus, the diffusion coefficient used in modeling SHS exceeds the experimental value by an order of magnitude
SHS wave in the Ti-Al system with the Ti-to-Al molar ratio of 1:3 in the charge mixture was modeled using E=200 kJ/mol and D0=4.39 cm2/s for phase TiAl3 [68] This E value was obtained from experiments on combustion synthesis using Arrhenius plots, and D0 was chosen to match the calculated and measured results of the propagation speed Again, these values refer to the SHS wave as a whole but not to interdiffusion in TiAl3 However, experimental data on SHS of TiAl3 for the same starting composition, which were analyzed using the classical
Trang 25combustion model [see Eqs (1.1),(1.2)], gave a substantially higher activation energy: E=483 kJ/mol [86] If solid-state diffusion in the TiAl3 layer is really the rate-limiting stage of the process, then the values of apparent activation energy ought to agree (within an experimental error) regardless of the particular form of a model
Diffusion coefficients are measured experimentally within a rather wide margin of error using a variety of techniques, and typically various methods yield different values But since diffusion parameters for many refractory compounds, which can be produced by combustion synthesis, can be found in literature, it appears possible to verify the validity of the diffusion-based kinetic model of SHS employing a somewhat opposite approach: estimating the product layer growth and heat release using the experimental characteristics of SHS and independent diffusion data The models, parameter values and results of simulations for two
classical CS-systems, viz Ti-C and Ni-Al, will be considered in more detail in the
subsequent chapters
Trang 26Chapter 2
CS
2.1 INTRODUCTION
CS in the Ti-C system was a subject of extensive theoretical and experimental studies [53,17,18,62,69] because of industrial significance of the product, titanium carbide, which is used for a wide range of applications because of its high melting point, hardness and chemical stability It is a suitable candidate for theoretical investigation for the following reasons: (i) the Ti-C phase diagram [87] (see Figure 2.1) contains only one binary compound TiC whose melting temperature
Tm(TiC)=3423 K exceeds the experimental SHS temperature TCS=3083 K [88] and (ii) numerous diffusion data for titanium carbide are available in literature [89-91] We consider the case of spherical symmetry which better fits a typical configuration of reacting particles in CS With respect to the phase diagram, here the solid-solid-liquid mechanism [situation C(solid)/TiC(solid)/ Ti(liquid)] is quasi-equilibrium and the solid-liquid mechanism [situation C(solid)/Ti(liquid)] is truly non-equilibrium
Let’s consider solid-state diffusion-controlled formation of the product, titanium carbide, during heating of the Ti+C charge mixture in the SHS wave Typical particle radii are 5 to 100 µm for Ti, about 0.1 µm for carbon black and 1
to 30 µm for milled graphite [17,18,69,88] Two scenarios with a different geometry of a unit reaction cell are examined: (1) a solid Ti particle surrounded
by carbon particles in a stoichiometric mass ratio at temperatures below the Ti melting point, Tm(Ti)=1940 K [Figure 2.2 (a and d)], and (2) a solid carbon particle surrounded by liquid titanium at T>Tm(Ti) [Figure 2.2 (c and e)]
Trang 27Figure 2.1 The equilibrium Ti-C phase diagram [87] and experimental SHS temperature
Trang 28Figure 2.2 Schematic of an elementary reaction cell in the SHS wave in the Ti-C system (a and c) and corresponding concentration profiles for solid-state diffusion (d and e) [60]: (a and d) growth of the TiC layer on the surface of a titanium particle at T<Tm(Ti); (b) rupture of the primary product shell and spreading of molten titanium at T=Tm(Ti); (c and e) growth of the TiC layer on the surface of a carbon particle after titanium melting and spreading at Tm(Ti)≤T≤TCS
A condition for the change of the reaction cell geometry due to titanium melting [Figure 2.2 (b)] is analyzed later
2.2 SCENARIO 1: GROWTH OF S TIC CASE ON THE
TITANIUM PARTICLE SURFACE
In scenario 1, at T<Tm(Ti) a thin uniform layer of TiC is formed on the surface of the Ti particle This is due to fast surface diffusion of C atoms from the Ti/C contact spots in the charge mixture, which agrees with the idea expressed in [88] Because of low carbon solubility in solid β-Ti and high diffusivity of C atoms in the β-phase as compared with that in TiC [90,91], we can consider the
growth of only one product phase-titanium carbide, i.e perform an upper-level
estimate of the product thickness Then the TiC layer growth in the SHS wave is described by a diffusion-type Stefan problem written in spherical symmetry neglecting a volume change at the Ti/TiC interface
Trang 29, (2.1)
where D is the chemical diffusion coefficient in TiC, which is usually associated with the diffusion coefficient of carbon in the carbide layer, cC is the mass concentration of carbon, R1(t) is the current position of the TiC/Ti interface, R2 is the outer radius of the Ti particle, and c01, c021 and c023 are the interface concentrations [Figure 2.2 (d)] according to the equilibrium phase diagram The boundary (at r=R2) and initial conditions to Eq (2.1) are
of C atoms across the TiC layer But at the C/TiC interface the growth of TiC at the expense of graphite, which requires the supply of Ti atoms, cannot occur Thus, the first-kind boundary condition, cC(t, R2)=c023 [see Eq (2.3)] is used for the C/TiC interface, which actually denotes an ideal “diffusion contact” of carbon particles with the outer surface of the growing TiC layer due to fast surface diffusion of the C atoms from the C/TiC contact spots
2.3 SCENARIO 2: GROWTH OF A TIC LAYER ON THE
SURFACE OF SOLID CARBON PARTICLES
The physical background for scenario 2 [Figure 2.2 (c)] is the following Spreading of molten titanium towards solid carbon in the SHS wave was observed experimentally [92,93] Since it is accompanied with chemical interaction, for a sufficiently small C particle size the spreading velocity is not the rate-limiting
D[T(t)]
t
2 C
(t) R
C 1
dt
dR )
Trang 30stage [93,94] Hence we consider that at T≥Tm(Ti) the carbon particles are completely enveloped with liquid titanium, and a thin TiC layer forms at the Ti/C interface separating the parent phases The product growth occurs at the
Ti(melt)/TiC interface, i.e outwards, due to diffusion of carbon atoms across the
TiC layer [Figure 2.2 (e)] Since the diffusion coefficient of carbon in the melt is
at least an order of magnitude higher than in the carbide (Table 2.1), it is reasonable to presume that the titanium melt is saturated with carbon (otherwise the TiC layer will be dissolving) Then the boundary condition at r=R0 to diffusion equation (2.1) and initial conditions to Eqs (2.1),(2.2) look as
cC(t, R0) = c023, cC(t, r>R1) = c01, R1(t=0) = R0, (2.4) where R0=const is the initial radius of the carbon particle
2.4 DIFFUSION DATA FOR TIC
The parameters for calculating the diffusion coefficient in TiC in the Arrhenius form
are listed in Table 2.1, wherein the experimental data available in literature 103] for different temperature intervals ΔT are collected It is seen that different data sources give substantially different values of both activation energy and preexponential factor, thus it seems necessary to select the parameters values suitable for numerical calculations Since the extrapolation of D to the whole temperature range of SHS may bring about overestimated values, the diffusion coefficients in TiC calculated at T=Tm(Ti) and TCS must be compared with the diffusion coefficient in molten titanium: it is obvious that the value of D in a solid metal-base refractory compound is at least an order of magnitude lower than in a melt of the corresponding metal
[95-Because of the absence of experimental data, the diffusion coefficient of C in molten Ti is estimated by a simple Stokes-Einstein (or Sutherland-Einstein) formula, which was used for assessing the diffusion parameters of C, N, O and H
in liquid metals (Fe, Co, Ni, etc.) [104,105]
Trang 31where numerical factor n=4 for substantially differing atomic radii of the melt
components and n=6 for close radii, ai is the atomic radius of i-th diffusing species in the melt, μ=ζρm is the dynamic viscosity, ζ is the kinematic viscosity and ρm is the liquid-phase density For carbon atoms, the covalent radius is
aC=0.077 nm [106] The density of molten Ti is ρm=4.11 g/cm3 [107] A typical
value of the kinematic viscosity for such liquid metals as Al, Fe, Co, Ni et al near
the melting point is (0.5-1)×10−2 cm2/s [106] For liquid titanium saturated with carbon, ζ=0.94×10−2 cm2/s at T=Tm(Ti) [107], then DC(m)(Tm) ≈ (4.8−7.2)×10−5
cm2/s For higher temperatures, the value ζ=1.03×10−2 cm2/s at T=2220 K is known [107]; using it at T=TCS gives DC(m)(TCS) ≈ (6.9−10.4)×10−5 cm2/s It should be noted that since Eq (2.6) doesn’t account for chemical interaction in the melt, which may be substantial for the Ti-C system, these DC(m) values are upper estimates Then the values of diffusion coefficients in TiC, which are close to or higher than the upper estimate of DC(m)(TCS), are excluded from consideration (lines 10 to 14 in Table 2.1)
Table 2.1 Diffusion data for titanium carbide
Trang 322.5 TEMPERATURE OF THE
REACTION CELL IN THE SHS WAVE
Self-heating from ambient temperature, T0, to TCS during the combustion synthesis is due to the adiabatic heat release of chemical reactions which are almost accomplished when maximal temperature is reached, and in the after-burn zone (at T≈TCS) only coalescence and sintering of the product particles occur with minor heat release [3-5] Hence calculations of the product layer thickness and relevant heat release should be done in the time interval [0, tCS] corresponding to the attainment of TCS
To perform calculations, we have to know the time dependence of temperature in the reaction cell, T(t) We consider a steady-state combustion regime For a low-temperature portion of the SHS wave, T0<T<Tm(Ti), where heat release is small, the temperature profile along a sample can be calculated using a known analytical solution [108]
T(ξ) = T0 + (Tm−T0)exp(−vSHSξ/κ), ξ = x − vSHSt, (2.7) where vSHS is the combustion velocity, x is a coordinate along the SHS-sample and κ is the thermal diffusivity To determine T(t) for the reaction cell, a coordinate x0 is chosen for which T(x0, t=0) = T0' = T0+0.01Tm, where T0=298 K Then the heating time, tm, from T0' to Tm is
(2.8)
For a stoichiometric Ti-C mixture (20 wt.% C), κ≈0.04 cm2/s [109] and vSHS=6 cm/s [88,18]
For higher temperatures, Tm≤T≤TCS, we use the spline-approximation of the experimental temperature profile of a steady-state SHS wave in the Ti-C system, which was registered by a micro-thermocouple technique [88] (Figure 2.3) It should be noted that the low-temperature tail [at T<Tm(Ti)] calculated by Eq (2.7) lies slightly above the corresponding part of the experimental curve, which is not shown in Figure 2.3 merely to avoid encumbering So, we use an upper estimate
of temperature (and hence the grown product layer) in the reaction cell In Figure
0 m
m 2
SHS
T 01 0 v
Trang 332.3, x=0 corresponds to the melting point of Ti, consequently the heating time from Tm(Ti) to TCS is ΔtCS = tCS−tm = x(TCS)/vSHS
Figure 2.3 Temperature profile of the SHS wave in the Ti-C system [60]: 1, analytical
solution for a steady-state SHS wave [Eq (2.7)] for T≤Tm(Ti); 2, cubic-spline
approximation of experimental curve [88] in the range Tm(Ti)≤T≤TCS
2.6 ADIABATIC HEAT RELEASE IN THE REACTION CELL
Having the heating law of the reaction cell, we can calculate the heat release due to diffusion-controlled phase layer growth in non-isothermal conditions and thus the maximal temperature attained, and then compare it with experimental
TCS In adiabatic conditions, a heat balance equation for the formation of stoichiometric TiC1.0 is written as:
−ΔH0
298(TiC1.0)mTiC(t) = mTiC(t) + mC(t) +
dT ) TiC ( c
ad
T
298 p
T
298 p
T
298 p
ad
Trang 34where Tad is the adiabatic combustion temperature, cp(i) is heat capacity, mi(t) is a current mass of i-th substance, ΔH0
298(TiC1.0) = −3.077 kJ/g is the standard enthalpy of TiC1.0 [110], ΔHm(Ti) = 0.305 kJ/g is the heat of fusion of Ti [110] and I[Tad−Tm(Ti)] is the Heaviside unit-step function The masses of all the substances are determined using a solution of the Stefan problem for particular geometry of the reaction cell, and then Tad is calculated from Eq (2.9)
2.7 MODELING OF TIC LAYER GROWTH ON THE TITANIUM
PARTICLE SURFACE
2.7.1 Analytical Solution to Scenario 1
Problem (2.1)-(2.3),(2.5) is non-linear and in a general case can be solved only numerically However, for a similar linear problem (with D=const) an asymptotic solution for the growth of a spherical phase layer, which is valid for a small layer thickness h=R2–R1 << R2, is known [25,111,112] To apply it, we linearize Eqs (2.2) and (2.3) using substitution
Here t varies from 0 to tCS, where tCS is time at which the temperature of the reaction cell reaches its maximal value TCS Then, according to [25,111], the asymptotic solution of Eqs (2.1)-(2.3) with respect to the product layer thickness,
h, looks as
h(τ) = R2 − R1(τ) = βτ1/2 + β1τ/R2 + β2τ3/2/(2R22), (2.11) where
=
τ (t) ∫ D[T( )] d
t
0
Trang 35π1/2(β/2)exp(β/2)2 erf(β/2) = q, (2.13) which arises in a similar Stefan problem for a semi-infinite sample
For scenario 1 [Figure 2.2 (a)], mTiC(τ) = (4/3)π[R23−R13(τ)]ρTiC, mC(τ) = mC0
− 0.2mTiC(τ), mTi(τ) = (4/3)πR13(τ)ρTi, where ρi is the density of i-th substance For a stoichiometric composition, the initial C-to-Ti mass ratio is mC0/mTi0 = 0.25, where mTi0 = (4/3)πR23ρTi Then, ignoring the temperature dependence of heat capacities in Eq (2.9), the maximal adiabatic heating of the reaction cell, ΔTad =
Tad−298, is estimated as
(2.14)
2.7.2 Results of Calculations for Scenario 1
In the temperature range T0'≤T≤Tm(Ti), equilibrium interfacial concentrations
c01= 0.00138 and c021=0.11 corresponding to the Ti-TiC eutectic temperature
Teu=1918 K [87] were used For higher temperatures, Tm≤T≤TCS, it was assumed that molten titanium remains inside the spherical TiC shell, and the interfacial compositions were taken for an intermediate temperature T=2673 K: c0=0.065,
c021=0.14 [87]; at the C/TiC interface c023=0.2 (maximal solubility of C in the carbide) Calculations have shown that varying the c021 and c01 values along the solidus and liquidus lines of the Ti-C phase diagram in the range T=Tm to TCS has
a negligible effect on the TiC layer thickness and associated heat release
For the temperature range T0'≤T≤Tm the calculations were performed with all the diffusion data listed in Table 2.1 [Figure 2.4 (a and b)] For the whole temperature range, T0'≤T≤TCS, only the data giving D(TCS)< DC(m) (lines 1 to 9 in Table 2.1) were used [Figure 2.4 (c and d)] A maximal TiC layer thickness attained by the time of reaching the titanium melting temperature is small, h(Tm)=0.068 µm [Figure 2.4 (a)], and corresponds to diffusion data No.14 in Table 2.1 The relevant adiabatic heating is insignificant, ΔTad=57 K for R2=10
µm [Figure 2.4 (b)], and decreases with increasing the particle radius For the temperature range T0'≤T≤TCS, the maximal TiC layer thickness corresponds to the set of diffusion parameters No 1 (see in Table 2.1), and this value is small: h(TCS)≈1.6 µm [Figure 2.4 (c)]
)]
( R ]/[R (C)R c 25 0 ) (Ti)R [c (C)]
c 2 (TiC) [c
) (TiC H
1 3 2 3 2 p 3
1 p Ti p p
TiC
TiC 0 0 298 ad
τ
− +
τ ρ
− ρ
ρ Δ
−
=
Δ
.
.
Trang 36Figure 2.4 Thickness of the TiC layer formed on the surface of a titanium particle by the time of attainment of Tm(Ti) (a) and TCS (c), and relevant adiabatic heating (b and d) [60] Numbers at curves correspond to diffusion data sets in Table 2.1
Trang 37The corresponding adiabatic heating is only ΔTad=1064 K for the Ti particle radius of 10 µm and sharply drops with increasing R2 [Figure 2.4 (d)] Thus, heat
release due to product growth is insufficient to sustain the SHS wave (i.e to reach
TCS=3083 K)
The obtained result, viz a small thickness of TiC grown in the temperature
range below Tm(Ti), qualitatively agrees with experimental data [17,18]: in rapidly cooled samples almost no interaction was observed in the so-called
“preheating zone” of the SHS wave
However, at the attainment of T=Tm(Ti) the melting of titanium can bring about the rupture of the primary TiC shell and the spreading of the metallic melt
It should be noted that in [69] the diffusion-controlled TiC formation was assessed using 6 different sets of the diffusion data, but only an isothermal situation below the titanium melting point was examined Besides, the TiC layer growth was considered on the surface of a carbon particle whereas, as mentioned above, the initial TiC film at T<Tm(Ti) will most probably form on the surface of solid Ti particles due to fast surface diffusion of C atoms
2.8 RUPTURE OF THE PRIMARY TIC SHELL
The density of solid β-Ti at T=Tm is ρs=4.18 g/cm3 while for molten titanium
at the same temperature ρm=4.11 g/cm3 [107] The conditions for the rupture of the TiC case because of the dilatation of the titanium core during melting can be determined from a continuity equation written for spherical symmetry [113]:
Ur(r) = Ar + B/r2, urr = ∂Ur/∂r = A − 2B/r3, uθθ(r) = Ur/r = A + B/r3,
(2.17)
Trang 38where urr and uθθ are the radial and shear strain, correspondingly, and A and B are constants which are determined from boundary conditions (2.16)
Hooke’s law for spherical symmetry looks as
σrr = [(1–ν)urr + 2νuθθ], σθθ = (uθθ + νurr),
(2.18)
where σrr and σθθ are the radial and shear stress, correspondingly, Y is the elastic modulus and ν is the Poisson’s ratio [113] Then the solution for σθθ is obtained from Eqs (2.16)-(2.18):
Rupture of the primary TiC shell occurs when the maximal shear stress in the spherical layer (at r=R2) exceeds the ultimate tensile stress σuts Then from Eq (2.19) we obtain a critical thickness, hcr = R2−R1, of the TiC layer:
, ,
The TiC case can burst at h≤hcr This is an upper estimate because we don’t take into account partial dissolution of TiC in molten titanium due to the eutectic reaction at 1645 °C
To calculate the hcr value, we have to determine the mechanical properties of TiC at the melting temperature of titanium The temperature dependencies of the elastic modulus, Y, and shear modulus, G, for TiC are known in the following form [96]:
) 2 1 )(
1
(
Y ν
− ν
+ ( 1 )( 1 2 )
Y ν
− ν +
f 1
f f p f 1
f 1 1 2
1
0 r 3
/ 1 m
s
γ +
− γ
− γ +
ρ ν
1
3 2
R 2
R
3
3 2
r 2 R
= R 1
hcr 2
3 / 1
0 uts
0 uts
) p (
p 2
+ σ
− ψ
= ϕ
ρ ν
Trang 39Y(T) = Y0 − bYTexp(−T0/T), G(T) = G0 − bGTexp(−T0/T), (2.21) where T0=320 K, Y0=461 GPa, bY=0.0702 GPa/K, G0=197 GPa and bG=0.0299 GPa/K Then at Tm(Ti)=1940 K we have Y=346 GPa and G=148 GPa, thus the Poisson’s ratio is ν = Y/(2G)−1 = 0.17 As for σuts values for TiC at elevated
temperatures, there are only disembodied data, e.g., σuts(T=1073 K) ≈ 380 MPa,
σuts(T=1273 K) ≈ 280 MPa [90] However, available are data on the bending strength, σb, of titanium carbide over a wide temperature range because it is a typical test for brittle refractory compounds; σb has a maximum of approximately
500 MPa around T=2000 K [96, page 233] Then, using an estimate σuts ~ σb/2 =
250 MPa, from Eq (2.20) we obtain hcr≈0.6R2 Since the calculated value h[T=Tm(Ti)] is very small, for any initial size of Ti particles used in SHS (R2=5 to
100 µm) melting of the titanium core will inevitably bring about the rupture of the primary TiC shell and spreading of the melt This changes the geometry of a unit reaction cell as shown in Figure 2.2 (a-c)
2.9 GROWTH OF A TIC LAYER ON THE SURFACE OF A SOLID
CARBON PARTICLE
2.9.1 Analytical Solution to Scenario 2
For scenario 2 [Figure 2.2 (c and e)], an asymptotic solution to Eqs (2.2),(2.3)-(2.5) with respect to the TiC layer thickness, h, can be obtained similarly to Eq (2.11) [25,111,112]:
h(τ) = R1(τ)− R0 = βτ1/2 − β1τ/R0 − β2τ3/2/(2R02) (2.22) Here coefficients β, β1 and β2 are defined, as previously, by Eqs (2.12),(2.13) and
τ is determined according to Eq (2.10) where integration is performed over the time range 0≤t≤ΔtCS, which corresponds to the temperature range Tm≤T≤TCS(Figure 2.3)
To calculate adiabatic heating, we turn to Eq (2.9) For the reaction cell shown in Figure 2.2 (c), mTiC(τ) = (4/3)π (R13(τ)−R03)ρTiC, mC(τ) = mC0 − 0.2mTiC(τ), mC0 = (4/3)πR03ρC and mTi(τ) = 4mC0 − 0.8mTiC(τ) Then, ignoring the temperature dependence of heat capacities and neglecting the melting enthalpy of
Trang 40titanium (because ΔHm(Ti) << |ΔH°298(TiC1.0)| [110]), the adiabatic heating of the reaction cell is estimated as
, (2.23) were subscript “m” denotes melt For calculations, the values of heat capacities (according to [110]) were taken at T=TCS Eq (2.23) refers to incomplete
conversion of carbon into titanium carbide, i.e when 0<ηTiC<1, where the degree
of conversion is expressed as
ηTiC = 1 − mC(τ)/mC0 = 0.2[R13(τ)/R03 − 1]ρTiC /ρC (2.24) For complete conversion ηTiC=1, the maximal adiabatic heating is ΔTad(max) =
−ΔH0
298(TiC1.0)/cp(TiC) = 3095 K, and the adiabatic SHS temperature Tad(max) =
298 + ΔTad(max) = 3393 K It is somewhat higher than the value Tad=3210 K calculated taking into account the temperature dependence of heat capacities [5,114] Thus, Eq (2.23) gives an upper estimate for ΔTad
2.9.2 Results of Calculations for Scenario 2
Numerical results are presented in Figure 2.5 The TiC layer thickness, which can form in the SHS wave with the temperature profile shown in Figure 2.3, was calculated using Eq (2.22) not accounting for the exhaustion of reactants [Figure 2.5 (a)] The maximal value is h≈1.5 µm for a sufficiently large carbon particle size, R0=12.5 µm, at the 1st set of diffusion data in Table 2.1
Adiabatic heating [Figure 2.5 (b)] was calculated taking into account the degree of conversion of carbon into carbide [see Eqs (2.23),(2.24)] A plateau with ΔTad=ΔTad(max) for small R0 values corresponds to complete conversion (ηTiC=1) Thus, from Figure 2.5 (b) it is seen that the diffusion-controlled growth mechanism can provide sufficient adiabatic heating to sustain the SHS process, which results from almost complete conversion, only for small-sized carbon particles: R0<3 µm
This contradicts numerous experimental works where SHS of TiC was performed with coarse-grained graphite: 7 µm [69,115,116], 20 µm [69,115], and
up to 63 µm [117] in diameter
] 1 )/R ( )]/[R (Ti c 4 (C) [c )]
(Ti c 8 0 (C) c 2 (TiC) [c
) (TiC H
0
3 1 m p p C m p p
p TiC
TiC 0
0 298 ad
− τ +
ρ +
−
− ρ
ρ Δ
−
=
Δ
.
.