Joining of NiAl to iron-based alloys by reactive casting

Nickel monoaluminide, NiAl, is exothermically synthesized from elemental liquids of aluminum and nickel and is simultaneously joined to iron-based alloys, such as carbon steels and stainless steels, by the reactive casting method, which is based on the pouring of the elemental liquids onto the base material. The exothermic reaction between the aluminum and nickel liquids produces extremely superheated NiAl liquid. Heat of the NiAl liquid is transferred to the base material, and the contact surface is melted to a depth depending on both the preheating temperature of the base material and the thickness of the NiAl produced. After solidification on the base material, NiAl is strongly joined to the base material, showing a joint strength exceeding the inherent strength of NiAl. The high joint strength is attributed to a very fine, rodlike eutectic structure at the joint interface that consists of a mixture of beta-NiAl and gamma-iron with an interrod spacing of approximately 100 nm.