Processing of FeAl/Al 2 O 3 IMCs Using Advanced Electrodeposition Methods
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PROCESSING OF FeAI/AI2 0 3 IMCs USING ADVANCED ELECTRODEPOSITION METHODS Brett Wilson, C.J. Suydam, M.J. Crimp and M.A. Crimp Department of Materials Science and Mechanics, Michigan State University, East Lansing, MI 48824-1226 ABSTRACT A theoretical examination of the FeAV/Al20 3 fiber intermetallic matrix composite (IMC) system was coupled with experimental results to determine optimum processing conditions for maximum FeAl adhesion to A120 3 fibers and minimum attraction of FeAl and A120 3 fibers to themselves. Optimizing the processing conditions leads to a more uniform green composite without matrix or reinforcement rich zones. The theoretical examination consisted of applying a model developed using traditional colloidal approaches to suspensions while accounting for the complexities of a multicomponent composite system. The model uses the suspension properties of the individual materials such as size and surface potential along with the processing conditions for the system as the basis for calculation. This model describes the interaction potentials between components of the suspension and the stability of and between various components of the system in terms of a stability ratio, W. The optimum processing conditions were found by determining the conditions under which the calculated values of W are ideal. Experimental results utilizing the model predictions have been examined and include verification of the FeAl particle adhesion to the A120 3 fiber and preliminary consolidation studies. INTRODUCTION As evidenced by this fifth MRS meeting on high temperature intermetallic alloys, intermetallics continue to receive considerable attention as potential moderate to high temperature materials. The B2 aluminides have been the focus of much of this attention because, in addition to their attractive high melting temperatures, they offer relatively low densities and the promise of excellent oxidation and environmental properties. Unfortunately, like many intermetallics, this class of alloys is limited by poor low temperature toughness and ductility, and limited high temperature strength. As a result, a large fraction of the current research now being focused on these materials is not for monolithic applications, but instead as matrix materials for advanced composites. The objective of these composites is to use large volume fractions of high strength fiber as the load carrying component in high temperature creep applications while taking advantage of the desirable properties of the intermetallic matrix. One of the hurdles in developing intermetallic matrix composites (IMCs) has been processing the reinforcement and matrix materials into a fully dense, well distributed product. A wide range of processes have been used to produce short fiber, whisker and particulant reinforced materials including hot pressing [1-4], hot extrusion [5], reactive sintering [1-3], powder injection [3] and XDb' [6]. Many of these methods have been used to successfully synthesize near fully dense, well dispersed composites. Production of co
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