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