<Emphasis Type="Italic">In-situ</Emphasis> reactive processing of nickel aluminides by laser-engineered net shaping |
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Authors: | Weiping Liu J N Dupont |
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Affiliation: | (1) the Department of Materials Science and Engineering, Lehigh University, 18015 Bethlehem, PA |
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Abstract: | Nickel aluminide intermetallics (e.g., Ni3Al and NiAl) are considered to be attractive materials for high-temperature structural applications. Laser-engineered net
shaping (LENS) is a rapid prototyping process, which involves laser processing fine metal powders into three-dimensional shapes
directly from a computer-aided design (CAD) model. In this work, an attempt has been made to fabricate aluminide intermetallic
compounds via reactive in-situ alloying from elemental powders using the LENS process. In-situ reactive alloying was achieved by delivering elemental Ni and Al powders from two different powder feeders, eliminating segregation
observed in the samples deposited by using the premixed elemental powders. Nickel aluminides of various compositions were
obtained easily by regulating the ratio of their feed rates. The aluminide deposits exhibited a high solidification and subsolidus
cracking susceptibility and porosity formation. The observed porosity resulted from a water-atomized Ni powder and can be
minimized or eliminated by the use of a N2-gas-atomized Ni powder of improved quality. Cracking was due to the combined effect of the high thermal stresses generated
from the LENS processing and the brittleness of the intermetallics. Crack-free deposits were fabricated by preheating the
substrate to a temperature of 450 °C to 500 °C during LENS processing. Compositionally graded Ni-Al deposits with a gradient
microstructure were also produced by the in-situ reactive processing. |
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