Injection Molding and Near-Complete Densification of Monolithic and Al2O3 Fiber-Reinforced Ti2AlC MAX Phase Composites

Near-net shape components composed of monolithic Ti2AlC and composites thereof, containing up to 20 vol.% Al2O3 fibers, were fabricated by powder injection molding. Fibers were homogeneously dispersed and preferentially oriented, due to flow constriction and shear-induced velocity gradients. After a two-stage debinding procedure, the injection-molded parts were sintered by pressureless sintering at 1250 °C and 1400 °C under argon, leading to relative densities of up to 70% and 92%, respectively. In order to achieve near-complete densification, field assisted sintering technology/spark plasma sintering in a graphite powder bed was used, yielding final relative densities of up to 98.6% and 97.2% for monolithic and composite parts, respectively. While the monolithic parts shrank isotropically, composite assemblies underwent anisotropic densification due to constrained sintering, on account of the ceramic fibers and their specific orientation. No significant increase, either in hardness or in toughness, upon the incorporation of Al2O3 fibers was observed. The 20 vol.% Al2O3 fiber-reinforced specimen accommodated deformation by producing neat and well-defined pyramidal indents at every load up to a 30 kgf (~294 N).

Effect of shape-memory alloy NiTi fiber on microstructure and mechanical properties of continuous ceramic Al2O3 fiber-reinforced Ti/Al3Ti metal–intermetallic laminated composite

Shape-memory alloy titanium nickel (NiTi) fiber was introduced into continuous ceramic aluminum oxide (Al2O3) fiber-reinforced titanium–titanium trialuminide metal–intermetallic laminated (CSMAFR-MIL) composite using vacuum hot pressing (HP) sintering method to improve the microstructure and mechanical properties of the composite. Scanning electron microscopy, energy-dispersive spectroscopy, and X-ray diffraction techniques were employed to characterize the microstructure of the novel CSMAFR-MIL composite. Besides, the tensile tests were carried out on continuous Al2O3 fiber-reinforced Ti-Al metal–intermetallic laminated (CFR-MIL) composite and the CSMAFR-MIL composite to explore the influence of NiTi fiber additive on mechanical behavior of the CFR-MIL composite. The experimental results showed that the intermetallic layer including Al3Ti, Al3Ti0.8V0.2, Al3Ni intermetallics but without residual NiTi fiber was generated via the reactions of liquid Al with NiTi fiber and Ti foil during preparation. Moreover, owing to the addition of NiTi fiber, intermetallic centerline was prevented effectively to form in the CSMAFR-MIL composite. Moreover, the elemental diffusion occurred between the Al2O3 fiber and the intermetallic, revealing that the metallurgical bonding was formed during the fabrication process. Furthermore, the CSMAFR-MIL composite possessed higher strength and superior ductility than those of CFR-MIL composite attributed to the microstructure optimization.