Freeze-off limits in transient liquid-phase infiltration

Transient liquid-phase infiltration (TLI) involves a powder-metal skeleton and an infiltrant with similar composition containing a melting-point depressant (MPD). Upon infiltration, the MPD diffuses into the skeleton, causing isothermal solidification and allowing a homogeneous final-part composition. Diffusional solidification of the infiltrant can restrict liquid flow and result in premature freeze-off if the liquid solidifies before filling the entire part. A capillary-driven fluid-flow model was developed to predict the infiltration rate and freeze-off limit using a variable skeleton permeability. Diffusional solidification was measured via quenching experiments, compared to theory, and used to define the change in permeability of the skeleton. The infiltration rate was measured via mass increase and compared to the flow model for various skeletons with powder sizes ranging from 60 to 300 µm. The predicted horizontal infiltration freeze-off limits were proportional to the square root of d3γ/μDβ2, where d is the average powder diameter, γ and μ are the infiltrant surface tension and viscosity, respectively, D is the solid diffusivity, and β is a function of the solidus and liquidus concentrations. These relations can be used for selection of processing parameters and for evaluation of new material systems.