Thermal Analysis of Self-Propagating High-Temperature Reactions in Titanium, Boron, and Aluminum Pow
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METALLURGICALANDMATERIALSTRANSACTIONSAVOLUME30A,MARCH1999—781ThermalAnalysisofSelf-PropagatingHigh-Temperature
ReactionsinTitanium,Boron,andAluminumPowder
Compacts
L.H.CHIU,D.C.NAGLE,andL.A.BONNEY
Thisarticlefocusesonthecharacterizationofself-propagatinghigh-temperaturesynthesis(SHS)
reactionsthatoccurinpowdercompactscontainingtitanium,boron,andaluminum.Interestinthis
powdersystemisbasedonthecriticalneedtodevelopnewjoiningtechniquesforbondingceramics
tometals.Theexothermicreactionsofparticularinterestinthisstudyincludethosethatgenerate
TiB2,TiB,Ti3Al,andTiAlfromtheirelementalpowders.Datafromdifferentialthermalanalysis
(DTA),thermogravimetricanalysis(TGA),andX-raydiffractometryarepresented.Theseresults
demonstratethatthegasphasesurroundingtheSHSpowdersplaysanimportantroleininitiating
theSHSreactionandindeterminingwhichreactionproductswillforminthefinalbond.
I.INTRODUCTION
FORtheoptimumperformanceofmanyaerospace,
commercial,andmilitarysystems,theuseofdissimilarma-
terialsisbecomingincreasinglynecessary.[1,2]Therefore,
thejoiningofadvancedmaterials,composites,andceramics
tometalstructuresisaprominentissue.[3]Thejoiningof
ceramicstometalspresentsaparticularlydifficulttask,due
tothedifferencesinmechanicalandthermalpropertiesof
thesematerials.Thesedifferencescanleadtoexcessive
stressatthejoininginterfaces,causingmechanicalfailure
intheformofmicrocracks.[4]Currenttechniquesforjoining
theseadvancedmaterialsincludetheuseofpolymer-based
adhesion,mechanicalfastening,andwelding.Ingeneral,
polymericadhesivesdonotenhancetheoverallperform-
anceofthestructure.Also,commerciallyavailablepoly-
mericadhesiveswilldegradeattemperatureshigherthan
180ЊC.[5]Thisseverelylimitstheapplicationsinwhich
polymericadhesivescanbeused.Mechanicalfasteners,
suchasboltsandsleeves,concentratestressesandincrease
thechancesofbrittlefractureand,ultimately,failureofthe
ceramicpart.Toalleviatetheseproblems,ceramicpartsare
oftenmetallized,whichaddsstepsinthemanufacturing
processandincreasesthetotalcostofthecomponent.[6]
Also,partsmustbedesignedtodistributestressesresulting
frommechanicalfasteningashomogeneouslyaspossible.
Welding,ontheotherhand,oftenresultsinoxidization
and/orrecrystallizationofthemetal,especiallywhenare-
pairisperformed.Manyweldingcompoundsdonotwet
ceramiccomponents.Differencesinthethermalexpansion
oftheweldmaterialandsubstratecanalsoleadtobond
failure.[6]Further,speciallytrainedweldersareusually
needed,whichaddstothecostofjoining.
Theultimategoalofthisresearchistoinvestigatethe
joiningofceramicstometalsbyself-propagatinghigh-tem-
L.H.CHIU,formerlywiththeMaterialScienceandEngineeringDepartment,JohnsHopkinsUniversity,iswithParatek,Inc.,Aberdeen,MD21001.D.C.NAGLEiswiththeMaterialScienceandEngineeringDepartment,JohnsHopkinsUniversity,Baltimore,MD21218.L.A.BONNEY,formerlywiththeMaterialsScienceandEngineeringDepartment,JohnsHopkinsUniversity,iswithBicron,Solon,OH44139.ManuscriptsubmittedJanuary13,1998.peraturesynthesis(SHS)reactions.Thermitereactionsin-
volvingmetal-oxidereactionshavebeenusedformany
decadestojoinsteelstructures.[7]Incontrasttothermite
reactions,theSHSreactionsareprimarilyusedtoproduce
refractorymetalcompoundsandceramicsfromcompacted
mixturesofelementalpowders.[8,9]Likethermitereactions,
SHSreactionsaretypicallyinitiatedbyheatingasmallpor-
tionofthepowdercompactwithahotfilamentorflame.
Onceinitiated,theexothermicheatissufficienttopropa-
gatethereactionthroughoutthemixture.Themainadvan-
tageofusingthismethodforjoiningisthegenerationof
hightemperatures(1200ЊCto4000ЊC)[10]forshortperiods
oftime,whichminimizestheheat-affectedzoneinthe
metal.TheveryhighheatoftheSHSreactioncanalso
desorbtheimpuritiesphysicallyadsorbedonthepowder
surfaces.[11]Thismethodoffersthepotentialforthefield
bondingofcomponentsatarelativelylowcost,sincethese
bondjointscanbemadewithalmostnocapitalequipment.
Manyofthesereactionscanbeinitiatedbya12Vbattery
andusuallyrequirenospecialtraining.
TheSHSreactionsinvestigatedinthisstudyaresimilar
toSHSprocessesdescribedbyNagleetal.[12]forformation
ofdiscontinuousmetal-matrixcomposites,whereceramic
reinforcementsareformedinsituinahostmetalmatrix.
Moshieretal.,[13]intheirpatent,revealamethodforbond-
ingmetalsandmetal-matrixcompositestoothermetal-
basedmaterialsbyweldingwithfillmaterialsthatare
metal-matrixcompositesgeneratedbySHS.Incontrast,the
goalofthisresearchistoutilizetheheatgeneratedfrom
theSHSprocesstobonddissimilarmaterialsinsitu,while
formingthemetal-matrixcompositethatisthebondma-
terial.
Thematerialstobebondedarealuminaceramic(Al2O3)
andtitaniummetal.TheSHSsystemchosentoformthe
bondisthecombinationoftitanium,aluminum,andboron
powders.TheSHSreactionofthesepowdersresultsinTiB2precipitatinginamatrixofTiAl,Ti3Al,orAl.Theconcept