Synthesis Of Bulk And Reinforced Nickel Aluminides By Reactive Infiltration

Preforms of nickel powder or nickel/alumina powder blends were infiltrated with molten aluminum to produce nickel aluminides. Application of a pressure of 3.6 and 6.9 MPa on the melt allowed infiltration of preforms with nickel powder particles between 5 and 15 mum in diameter, which could not be infiltrated under the sole action of capillary forces. By varying the initial preform temperature from 705-degrees-C to 280-degrees-C, the diameter of nickel powder particles from 15 to 150 mum, and the volume fraction of alumina from 0 to 34 vol pct, pressure-infiltrated samples with large variations in the extent of reaction between nickel and aluminum were produced. The range of microstructure extended from fully reacted nickel aluminide to essentially unreacted nickel/aluminum samples containing low levels of final porosity. In particular, it was found that reducing the initial preform temperature below the melting point of aluminum results in a reduction of the rate and extent of aluminide formation, allowing, in turn, reduction of macrosegregation within the resulting infiltrated material.