Near net-shape/net-dimension ZrC/W-based composites with complex geometries via rapid prototyping and Displacive Compensation of Porosity |
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| Authors: | David W. Lipke Yunshu Zhang Yajun Liu Benjamin C. Church Kenneth H. Sandhage |
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| Affiliation: | 1. School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA;2. School of Chemistry and Biochemistry, Georgia Institute of Technology, Atlanta, GA 30332, USA;1. National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”, 37, Peremogy Ave., Kyiv, 03056, Ukraine;2. KU Leuven, Department of Materials Engineering, Kasteelpark Arenberg 44, B-3001, Heverlee, Belgium;3. Institute of Materials and Joining Technology, Otto-von-Guericke University Magdeburg, Universitätsplatz 2, 39106, Magdeburg, Germany;1. Institute for Language and Speech Processing, Multimedia Department, Research Centre “Athena”, PO BOX 159, 67100 Xanthi, Greece;2. University of Ljubljana, Faculty of Civil and Geodetic engineering, 1000 Ljubljana, Slovenia;3. Democritus University of Thrace, Faculty of Electrical and Computer Engineering, 67100 Xanthi, Greece;1. Structural Materials Group, Institute of Nuclear Materials Science, SCK CEN, 2400, Mol, Belgium;2. Institute of Mechanics, Materials and Civil Engineering, UCLouvain, 1348, Louvain-la-Neuve, Belgium;3. Institute of Solid State Physics, Chinese Academy of Sciences, Hefei, Anhui, 230031, China;4. Department of Electrical Energy, Metals, Mechanical Constructions & Systems, Ghent University, 9052, Ghent, Belgium;5. Department of Materials Science and Engineering, Delft University of Technology, Delft, 2082, the Netherlands |
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| Abstract: | ZrC/W-based composites with complex shapes have been fabricated by combining rapid prototyping methods for synthesizing porous WC preforms with the shape/dimension-preserving, reactive infiltration-based Displacive Compensation of Porosity (DCP) process. Two automated rapid prototyping methods were examined: (i) computer-numerical-controlled machining of porous WC powder compacts, and (ii) 3D printing of WC powder. After binder removal and partial sintering (to neck the WC particles), the shaped, porous, and rigid preforms were exposed to molten Zr2Cu at 1150–1300 °C and ambient pressure. Upon infiltration, the Zr in the melt underwent a displacement reaction with WC to yield more voluminous ZrC and W products that filled prior pores (reaction-induced densification). The resulting ZrC/W-based composites retained the shapes and dimensions (to within 1%) of the WC preforms. This work demonstrates, for the first time, that rapid preform prototyping can be integrated with the DCP process to generate dense, ultrahigh-melting carbide/refractory metal composites with tailorable near net-shapes and -dimensions. |
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