Microstructure evolution in metal-intermetallic laminate (MIL) composites synthesized by reactive foil sintering in air

Metal-intermetallic (aluminide) laminate (MIL) composites have been fabricated in air using dissimilar metal foils. Foils of varying Al thickness were reacted with foils of Ti-3Al-2.5V resulting in microstructures of well-bonded metal-intermetallic layered composites with either Ti or Al residual metal layers alternating with the Al3Ti intermetallic layers. The MIL composites exhibit a very high degree of microstructural design and control. Microstructure characterization by scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffractometry (XRD) has been performed, and basic physical properties of the Ti-Al composites have been determined. The Ti-Al reaction has been studied by interrupting the reaction processing, in steps, to observe the microstructural changes. An oxide layer between the Ti and Al foils initially controls the reaction kinetics. After breakdown of the oxide layer, a two-phase Al + Al3Ti layer (similar to 10 mum thickness) is formed. After formation of the two-phase layer, liquid phases are continuously present, and Al3Ti spherules (similar to 10 mum diameter) are formed through interfacial tension, solidify tin times of 2 to 4 mus), and are expelled into the liquid. This mechanism allows for a continuous reaction interface and higher reaction rates. Both reaction regimes, diffusion through the oxide, and, subsequently, the intermetallic phase reaction mechanism result in linear kinetics.