Induction-activated self-propagating, high-temperature synthesis of nickel aluminide

Indirect Induction Sintering of Metal Parts Produced through Material Extrusion Additive Manufacturing

Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being increasingly used, resulting in almost fully dense parts, whereby geometries are shaped, debinded and sintered sequentially until the completion of the part. Traditionally, "brown" debinded geometries are transported to conventional furnaces to densify the powder compacts, requiring careful tailoring of the heating profiles and sintering environment. This approach is decoupled and often involves time-consuming post-processing, whereby after the completion of the shaping and debinding steps, the parts need to be transported to a sintering furnace. Here, it is shown that sintering via indirect induction heating of a highly filled commercially available filament embedded with stainless steel 316L powder can be an effective route to densify Fused Filament Fabricated (FFF) parts. The results show that densities of 99.8% can be reached with very short soaking times, representing a significant improvement compared to prior methods. A hybrid machine is proposed, whereby a custom-built machine is integrated with an induction heater to combine FFF with local indirect induction sintering. Sintering in situ, without the need for part transportation, simplifies the processing of metal parts produced through material extrusion additive manufacturing.

Preparation and Study of Composite Materials of the NiAl-Cr-Mo-Nanoparticles (ZrO2, MgAl2O4) System

Materials based on the NiAl-Cr-Mo system with zirconium oxide or aluminum-magnesium spinel nanoparticle small additions were obtained by spark plasma sintering. Thermodynamic modeling was carried out to predict the phase formation in the NiAl-Cr-Mo system and its change depending on temperature, considering the presence of a small amount of carbon in the system. The phase composition and microstructure of materials were studied. NiAl (B2) and CrMo phases were found in the sintered samples. Bending strength measurements at different temperatures shows that nanoparticles of insoluble additives lead to an increase in bending strength, especially at high temperatures. A fractographic analysis of the sample's fractures shows their hybrid nature and intercrystalline fracture, which is confirmed by the clearly visible matrix grains similar to cleavage. The maximum strength at 700 °C (475 MPa) was found for material with the addition of 0.1 wt.% zirconium oxide nanoparticles. In the study of internal friction, typical peaks of a nickel-aluminum alloy were found in the temperature ranges of 150-200 °C and 350-400 °C.

The role of interlayer gases and surface asperities in compression-induced intermetallic formation in Ni/Al nanocomposites

Reactive composites composed of alternating nano- or microscale layers of Ni and Al are known to undergo self-sustaining alloying reactions under compression-loading, however the effect of infiltrated gas within the...

Synthesis of Metal Matrix Composites Based on CrxNiy-TiN for Additive Technology

The novelty of this work consists of obtaining original fundamental data on the laws of synthesis of new metal matrix composite materials for additive technologies. CrN + TiNi composites were obtained using the method of self-propagating high-temperature synthesis. In this work, analysis of the parameters of the synthesis of composite materials as well as their structure and phase composition were carried out. A scheme for the formation of a composite structure is established; it is shown that the phase composition is represented by 54.6 wt.% CrN and 45.4 wt.% TiNi. It was shown that composites based on the system are suitable for machines that make use of direct laser deposition to grow layers of materials. Sample structure and phase parameters were studied. It is shown that titanium nitride particles are uniformly distributed in the CrNi intermetallic matrix, the TiN particle size ranges from 0.3 to 9 μm and the average particle size is 2.8 μm. The results obtained indicate the possibility of synthesizing promising metal matrix composite materials for additive technologies. Such materials may have increased hardness, operating temperature and strength.

High-Temperature Synthesis of Metal–Matrix Composites (Ni-Ti)-TiB2

Currently, metal–matrix composite materials are some of the most promising types of materials, and they combine the advantages of a metal matrix and reinforcing particles/fibres. Within the framework of this article, the high-temperature synthesis of metal–matrix composite materials based on the (Ni-Ti)-TiB2 system was studied. The selected approaches make it possible to obtain composite materials of various compositions without contamination and with a high degree of energy efficiency during production processes. Combustion processes in the samples of a 63.5 wt.% NiB + 36.5 wt.% Ti mixture and the phase composition and structure of the synthesis products were researched. It has been established that the synthesis process in the samples proceeds via the spin combustion mechanism. It has been shown that self-propagating high-temperature synthesis (SHS) powder particles have a composite structure and consist of a Ni-Ti matrix and TiB2 reinforcement inclusions that are uniformly distributed inside it. The inclusion size lies in the range between 0.1 and 4 µm, and the average particle size is 0.57 µm. The obtained metal-matrix composite materials can be used in additive manufacturing technologies as ligatures for heat-resistant alloys, as well as for the synthesis of composites using traditional methods of powder metallurgy.