SYNTHESIS OF INTERMETALLICS BY MECHANICAL ALLOYING

Mechanical alloying (MA), a solid-state powder processing method, is a 'far from equilibrium' synthesis technique which allows development of novel crystal structures and microstructures, leading to enhanced physical and mechanical properties. The ability to synthesize a variety of alloy phases including supersaturated solid solutions, nanocrystalline structures, amorphous phases and intermetallic compounds themselves is discussed. No extension of solubility using MA has been observed in the intermetallics studied. Nanostructured grains were observed in all compositions. Long time milling generally resulted in amorphous phase formation in large part because of the increase in grain boundary energy/mole with reduced grain size; good agreement with the Miedema model for amorphization was obtained in the Al-Fe system. Generally an anneal was required to form the intermetallic after MA; however,intermetallics with a large negative enthalpy of formation were detected in the MA condition. A study of the hot isostatic pressing of γ-TiAl powders produced by MA demonstrated that full density can be achieved at least 400℃ below the normal temperature required for conventional powder, that is 725℃ or below. Nanometered sized grains (≤100nm)were observed after HIP'ing up to 850℃.

Influence of mechanical alloying time on the properties of Fe_3Al intermetallics prepared by spark plasma sintering

The Fe3Al-based intermetallics were prepared by mechanical alloying and spark plasma sintering （SPS）, and the influence of milling time on the properties of materials was investigated. The phase identification was investigated by X-ray, and the surface morphology and fractography were observed by scanning electron microscope （SEM）. The mechanical properties such as bending strength, strain, and microhardness were tested. The results show that Fe reacts with Al completely to form Fe3Al during short SPS processing time. The relative densities of the sintered samples were nearly 100%. The mechanical properties of the sintered samples can be improved along with the milling time. The representative values are the bend strength of 1327 MPa and the microhardness of 434.

CHARAC TERIZATION OF TiAl POWDER PRODUCED BY MECHANICAL ALLOYING

The microstructure,alloying reaction and sintering behavior of the powder produced by Mechanical Al-loying(MA)for 8 h from 64 wt.-% Ti powder and 36 wt.-% Al powder were studied by scanning electronmicroscopy,optical microscopy,X-ray diffractometry,differential scanning calorimetry(DSC)and dilatometry.The mechanically alloyed powder partictes are Ti-Al composite particles.Thus,titanium aluminides can formeasily in the powder through diffusion during heat treatment.It is shown that the sintering behavior of this pow-der,different from the behaviors of TiAl alloy powder and mixed powder of 64 wt.-% Ti powder and 36 wt.-%Al powder,changes from expansion at temperatures below 1000℃ to shrinkage at temperatures above 1000℃.Homogeneously alloyed TiAl material with a density over 96% of the theoretical density can be produced fromthe mechanically alloyed powder by compaction-sintering.

Formation mechanism of Ti_5Si_3 powder by mechanical alloying

The formation mechanism of stoichiometry Ti_5Si_3 by mechanical alloying (MA)from elemental powders has been investigated. The results of XRD and SEM analyses of the powdershow that Ti_5Si_3 can be synthesized by MA in a planetary mill with two different formationmechanisms. Ti_5Si_3 was formed gradually with the mechanical collusion reaction (MCR) mechanismunder a lower impact energy, and the Ti_5Si_3 was formed abruptly with the self-propagatinghigh-temperature synthesis (SHS) formation mechanism under a higher impact energy.

A COMPONENT-SPECIFIC ALLOY DESIGN OF TiAl INTERMETALLICS

The metallographic observation and analyses of TiAl alloy cast ingots revealed that the preferably arranged γ/α_2 lamellar microstructure can be obtained in columnar dendritic cast ingot through controlling the Ti/Al atomic ratio. The experiments conf irmed that the preferably arranged γ/α_2 lamellar microstructure has excellent tensile strength and fracture toughness and tolerant tensile plasticity when the stress is applied parallel to the γ/α_2 interface.Based on these results and the working condition of the turbine blades,a component-specific alloy design has been suggested.

Influence of process control agents on the performance of Ni_3Al by mechanical alloying

The influence of process control agents （PCAs） on the mechanical properties of Ni3AI intermetallic compounds by mechanical alloying was investigated in order to develop oxide deposition reinforced intermetallics. The PCAs in mechanical alloying were pure ligroin, 75 vol.% ligroin ＋ 25 vol.% alcohol, 50 vol.% ligroin ＋ 50 vol.% alcohol, 25 vol.% ligroin ＋ 75 vol.% alcohol, and pure alcohol. The normal composition is Ni-22.9at.%Al-0.5at.%B, the ball-to-powder weight ratio is 10：1, and the milling time is 30 min. Then, the powders were sintered by spark plasma sintering under 40 MPa for 5 min at 1000℃. The results show that a higher bending strength and a higher hardness were obtained when the PCAs were 75% ligroin ＋ 25% alcohol in mechanical alloying. The bending strength is about 2700 MPa and the hardness （HV） is more than 6 GPa.

Recent developments in engineering γ-TiAl intermetallics

TiAl based alloys are rapidly being developed for elevated temperature applications, due to their high strength, light mass and good oxidation resistance. However, the disadvantages of TiAl based alloys are low ductility and toughness at room temperature, and poor workability. Grain refinement is one of the most effective ways for improving room temperature tensile properties and hot workability of ordered TiAl based alloys. At present, the majority of research works have focused on alloy modifications through compositional controls, alloying additions, thermo mechanical processing and production techniques. This article discusses the research status of TiAl based alloys in the areas of microstructure, alloying, processing and applications.

Mechanical alloying and characteristics of spark plasma sintering of Ti-Al composite powders

The mechanical alloying process of Ti-Al composite powders were carried out by use of high energy ball-milling machine. Structure variations of powder mixtures during mechanical alloying and characteristic of spark plasma sintering were investigated. The results show that during milling,TiAl,Ti3Al and Ti2Al phase intermetallic compounds are formed,simultaneously with powder refinement for the(TiH2-45Al-0.2Si-5Nb) and(TiH2-45Al-0.2Si-7Nb) mixtures. The particle sizes of two powder mixtures are less than 300 nm after milling for 30 h. Sintering process of the milled powder can be completed in a short time by spark plasma sintering,and the sintering microstructure is composed of fine and homogeneous TiAl and Ti3Al phase.

SYNTHESIS OF NANO－METER TiAl INTERMETALLIC COMPOUND THROUGH MECHANICAL ALLOYING

The transformation process of mixture of elemental Al and Ti powders during mechanical alloying was investigated.Results show that Al-Ti amorphous phase and then TiAl intermetallic compound form.The TiAl intermetallic compound produced by mechanical alloying is nanocrystalline with disordered structure.

Microstructure and Mechanical Properties of FeAl Intermetallics Prepared by Mechanical Alloying and Hot-Pressing

FeAl intermetallics were prepared by mechanical alloying and vacuum hot-pressing. The Fe-48 at.% Al powder was ball-milled for 3-12 h, producing a solid solution structure of Fe （Al） with trace Al （Fe）. Subsequent vacuum annealing or hot-pressing introduced phase transformations into the FeAl （B2） intermetallics and Al2O3 inclusions. The hot-pressed FeAI intermetallics possess a high flexural strength of 831 MPa and a fairly good strain at break of 3.2%. The results show that the addition of 0.5 at.% B reduces the peak temperature for hot-pressing from 1180℃ to 1100℃, and increases the density of the compacts from 95% to 96.3%, but results in no significant improvement in the mechanical properties.

Thermodynamic Aspects of Nanostructured CoAl Intermetallic Compound during Mechanical Alloying

The nanostructured CoAl intermetallic compound was produced by mechanical alloying （MA） of the Co50Al50 elemental powder mixture in a planetary high energy ball mill. The ordered B2-CoAl structure with the grain size of about 6 nm was formed via a gradual reaction after 10 h of MA. A thermodynamic analysis of the process was also done. The results showed that the intermetallic compound of CoAl had the minimum Gibbs free energy compared to solid solution and amorphous states indicating the initial MA product was the most stable phase in the Co-Al system which was changed to a partially disordered structure with a steady long-range order of 0.82 at further milling. This amount of disordering caused the enthalpy of final product to show an increase of about 5.1 kJ·mol-1. Calculation of enthalpy related to the triple defect formation revealed that the enthalpy required for Al anti-sites formation was about 3 times greater than that for Co anti-sites formation.

Microstructure Characteristics and Elevated Temperature Mechanical Properties of a B Containedβ-solidifiedγ-TiAl Alloy

The improved microstructure and enhanced elevated temperature mechanical properties of Ti-44Al-5Nb-(Mo,V,B)alloys were obtained by vacuum arc re-melting(VAR)and primary annealing heat treatment(HT)of 1260℃/6 h/Furnace cooling(FC).The phase transformation,microstructure evolution and tensile properties for as-cast and HTed alloys were investigated.Results indicate that three main phase transformation points are determined,T_(eut)=1164.3℃,T_(γsolv)=1268.3℃and T_(βtrans)=1382.8℃.There are coarse lamellar colonies(300μm in length)and neighbor reticular B2 andγgrain(3-5μm)in as-cast alloy,while lamellar colonies are markedly refined and multi-oriented(20-50μm)as well as the volume fraction and grain sizes of equiaxedγand B2 phases(about 15μm)significantly increase in as-HTed alloy.Phase transformations involvingα+γ→α+γ+β/B2 and discontinuousγcoarsening contribute to the above characteristics.Borides(1-3μm)act as nucleation sites forβ_(eutectic) and produce massiveβgrains with different orientations,thus effectively refining the lamellar colonies and forming homogeneous multi-phase microstructure.Tensile curves show both the alloys exhibit suitable performance at 800℃.As-cast alloy shows a higher ultimate tensile stress of 647 MPa,while a better total elongation of more than 41%is obtained for as-HTed alloy.The mechanical properties improvement is mainly attributed to fine,multi-oriented lamellar colonies,coordinated deformation of homogeneous multi-phase microstructure and borides within lamellar interface preventing crack propagation.

Effect of spark plasma sintering temperature on microstructure and mechanical properties of melt-spun TiAl alloys

A TiAl alloy from pulverized rapidly solidified ribbons with the composition of Ti-46Al-2Cr-4Nb-0.3Y（mole fraction,%） was processed by spark plasma sintering（SPS）.The effects of sintering temperature on the microstructure and mechanical properties were studied.The results show that the microstructure and phase constitution vary with sintering temperature.Sintering the milled powders at 1200 ℃ produces fully dense compact.Higher sintering temperature does not improve the densification evidently.The dominant phases are γ and α2 in the bulk alloys sintered at 1200 ℃.With higher sintering temperature,the fraction of α2 phase decreases and the microstructure changes from equiaxed near γ grain to near lamellar structure,together with a slight coarsening.The bulk alloy sintered at 1260 ℃ with refined and homogeneous near lamellar structure reveals the best overall mechanical properties.The compressional fracture stress and compression ratio are 2984 MPa and 41.5%,respectively,at room temperature.The tensile fracture stress and ductility are 527.5 MPa and 5.9%,respectively,at 800 ℃.

High Temperature Corrosion and Protection of Titanium Alloys and TiAl Intermetallics

High temperature corrsoion and protection of trtanium alloys and TiAl intermetallics are reviewed, andsome suggestions on the development of protective coatings are put forward.

Vacuum brazing TiAl intermetallic to K4169 alloy using amorphous filler metals Ti_(56.25–x)Zr_(x)Ni_(25)Cu1_(8.75)

A series of Ti_(56.25-x)Zr_(x)Ni_(25)Cu1_(8.75)(x=0–25,at.%) filler metals were designed based on a cluster-plus-glue-atom model to vacuum braze TiAl intermetallic to K4169 alloy. The impact of Zr content on the interfacial microstructure and shear strength of joints was examined. And the relationship between the interfacial lattice structure and the fracture behavior of the joint was investigated. The findings reveal a sectionalized characteristic with three reaction zones (Zone I, Zone II and Zone III) in the microstructure of the TiAl intermetallic to K4169 alloy joint. As the Zr content in filler metals increased, the diffusion of Ti transitioned from long-distance to short-distance in Zone I, changing the initial composition from TiNi_(3) /TiNi/NiNb/(Cr, Fe, Ni)SS to NiCrFe/(Cr, Fe, Ni)SS /TiNi. In Zone II, the initial composition altered from TiNi_(3) /TiNi to TiNi/Ti_(2) Ni/TiNi_(3) /TiCu/TiNi. The interface between Zones II and III altered from a non-coherent and semi-coherent interface of TiNi/TiAl/Ti_(3) Al with significant residual stress to a semi-coherent interface of TiNi/TiNi_(3) /TiAl_(2) /Ti_(3) Al with a gradient distribution. The shear strength of the joint initially decreased and then increased. When the Zr content of filler metal was 25 at.%, the shear strength of the joint reached 288 MPa. The crack initiation position changed from non-coherent TiNi/TiAl interface with high angle grain boundaries (HAGBs) and lattice mismatch of 65.86 at.% to a semi-coherent Ti3 Al/TiAl2 interface with a lattice mismatch of 20.07 at.% when the Zr content increased. The brittle fracture was present on the fracture surfaces of all brazed joints.

Characterization of Mo–Si–B Nanocomposite Powders Produced Using Mechanical Alloying and Powder Heat Treatment

Mo-Si-B nanocomposite powders with a composition of Mo-12Si-8.5B （in at.%） were processed using mechanical alloying under milling conditions for different milling time and powder-to-ball ratios. The Mo-12Si-8.5B alloy, which consists of α-Mo and intermetallic Mo3Si and T2 phases, was also synthesized by hot-pressed sintering the mechanically alloyed powders under a pressure of 50 MPa at 1600 ℃. The results demonstrated that the sizes and morphologies of the powder particles became gradually refined and uniform by both increasing the milling time and decreasing the powder-to-ball ratio. After 15 h of milling, the powders were completely homogenized at the 1：10 and the 1 ： 15 powder-to-ball weight ratios, and the homogenization was accelerated to rapidly stabilize the milling process because of their high milling energy. Annealing the Mo-Si-B milled powders could promote the growth of the intermetallic Mo3Si and the T2 phases, which formed even after low-temperature annealing at 900 ℃. Increasing the annealing temperature only improved the crystallinity of various phases. When the milled and annealed powders were hot-pressed sintered, the Mo-Si-B alloy exhibited a fine-grained microstructure, where the intermetallics Mo3Si and T2 were distributed in a continuous α-Mo matrix.

Effects of annealing on microstructure and mechanical properties of γ-TiAl alloy fabricated via laser melting deposition

The microstructure evolution and mechanical properties of the as-deposited γ-TiAl-based alloy specimen fabricated via laser melting deposition and as-annealed specimens at different temperatures were investigated.The results show that the microstructure of as-deposited specimen is composed of fineα2(Ti3Al)+γlamellae.With the increase of annealing temperature,the bulk γ m(TiAl)phase gradually changes from single γ phase toγphase+acicularα2 phase,finally small γ phase+lamellar α2+γ phase.Compared with the mechanical properties of as-depositedγ-TiAl alloy(tensile strength 469 MPa,elongation 1.1%),after annealing at 1260℃ for 30 min followed by furnace cooling(FC),the room-temperature tensile strength of the specimen is 543.4 MPa and the elongation is 3.7%,which are obviously improved.

Influence of Mo content on microstructure and mechanical properties of β-containing TiAl alloy

The influence of Mo content on the microstructure and mechanical properties of the Ti?45Al?5Nb?xMo?0.3Y(x=0.6,0.8,1.0,1.2)alloys was studied using small ingots produced by non-consumable electrode argon arc melting.The results show that smallquantities ofβphase are distributed alongγ/α2lamellar colony boundaries as discontinuous network in the TiAl alloys owing to thesegregation of Mo element.Theγphase forms in the interdentritic microsegregation area when the Mo addition exceeds0.8%.Theβandγphases can be eliminated effectively by subsequent homogenization heat treatment at the temperature above Tα.The evolutionof the strength,microhardness and ductility at different Mo contents under as-cast and as-homogenization treated conditions wasanalyzed,indicating that excessive Mo addition is prone to cause the microsegregation,thus decreasing the strength andmicrohardness obviously,which can be improved effectively by subsequent homogenization heat treatment.

Mechanical properties of TiAl fabricated by electron beam melting-A review

As a typical intermetallic material,TiAl is inevitably difficult to process by conventional methods.Additive manufacturing(AM)has recently become a new option for making net-shape TiAl components.Among all AM methods,electron beam melting(EBM)shows the potential to make TiAl components with good mechanical properties and is used for low pressure turbine blades.The mechanical properties,including tensile and compression properties,fracture toughness,fatigue and creep properties of EBM TiAl are reviewed and compared to the conventionally fabricated alloys.Results show that the tensile strength of EBM alloys is higher than cast alloys,and other properties are comparable to the cast/forged alloys.The sensitivity of mechanical properties and microstructure to EBM processing parameters is presented.Issues including layered microstructure,anisotropy in mechanical properties,and fatigue failure from defects are also reviewed.Finally,some opportunities and challenges of EBM TiAl are identified.

FRACTURE MECHANISM AND MICROMECHANICAL ANALYSIS OF POLYSYNTHETICALLY TWINNED CRYSTALS OF γTiAl ALLOYS

The fracture behavior and mechanism of PST crystals of a Ti 49%(mole fraction)Al alloy have been studied by using in situ straining and micromechanical calculation. The three dimensional micromechanical model representing the structure of PST crystal has been built, and the stress distribution ahead of the sharp and blunt crack tips either parallel to lamellar interface or perpendicular to the lamellae has been calculated by using finite element method based on linear elasticity of PST crystals. The experimental results show that the fracture behaviors and mechanisms are strongly dependent on the angle of loading axis to the lamellae. The calculation indicates that nucleation and propagation of microcrack along the interfaces are controlled by the normal stress and translamellar microcrack is controlled by shear stress ahead of crack tip.