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In situ TiCFeAl2O3TiAl/Ti3Al composite coating processing
using centrifugal assisted combustion synthesis
Reza Mahmoodian a,d,, M.A. Hassan a,e, M. Hamdi a, R. Yahya b, R.G. Rahbari c
a Centre of Advanced Manufacturing and Materials Processing (AMMP), Department of Mechanical Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysiab Department of Chemistry, Faculty of Science, University of Malaya, 50603 Kuala Lumpur, Malaysiac Restorative Dentistry Department, Dentistry Faculty, University of Toronto, Toronto, ON M5G 1G6, Canadad Department of Research and Development, Azarin Kar Ind. Co., Industrial Zone 1, 7635168361 Kerman, Irane Department of Mechanical Engineering, Assiut University, Assiut 71516, Egypt
a r t i c l e i n f o
Article history:
Received 24 March 2013
Received in revised form 25 October 2013
Accepted 17 December 2013
Available online 23 December 2013
Keywords:
A. Ceramicmatrix composites (CMCs)
A. Intermetallics
E. Joints/joining
Functional graded coatings
a b s t r a c t
The composite coating of a titanium carbide aluminidealumina-iron composite was synthesized by
centrifugal-assisted self-propagating high-temperature synthesis (SHS). The in situ TiCAl2O3Fe with
intermetallic phases of titanium aluminide (TiAl/Ti3Al) possesses excellent metallurgical properties. This
composite was produced from compacted titanium (Ti) and carbon (C) powders in the form of pellets
embedded in a tube, which were exposed to very high temperature generated by the thermite Fe2O3and Al reaction. The process took place in a graphitesteel tube mounted in a centrifugal accelerator
machine purposely developed for this function. Functionally graded coating was produced under the
centrifugal acceleration field and the product of the thermite reaction (Al2O3 and Fe) infiltrated the TiC
pellet and to create a strong, titanium aluminide intermetallic layer. The centrifugal force significantly
enhanced both metallurgical alloying and mechanical interlocking between different sample layers
during product formation. The purpose of the research addresses the applications of local reinforcement
of the ceramic-lined tubes.
2013 Elsevier Ltd. All rights reserved.
1. Introduction
Self-propagating high-temperature synthesis (SHS) leads to the
in situ production of composites with reactive initial substances
through an exothermic chemical reaction [1]. The heat generated
by the reaction ignites and sustains a propagating combustion
wave through the reactants as the anticipated product is created
[2]. SHS is characterized as a high-temperature process that makes
it an alternative, more economical method for ceramic industries
compared to conventional ceramic processing. SHS is a feasible
technique for the preparation of advanced ceramics, catalysts and
nanomaterials[3].
The centrifugal SHS process of Fe2O3 and Al is a spontaneous
reaction propagation and simultaneous rapid synthesis under the
effect of centrifugal acceleration. The reaction occurs in the inner
surface of the centrifugal tube where the Al melts and Fe2O3 re-
duces in the initial stage[4]. The self-sustained exothermic reac-
tion propagates through a pre-mixed powder in the form of a
high-temperature reaction wave with rapid heating rate and short
reaction time. This is followed by phase separation and solidifica-
tion of the Al2O3 and Fe products[5]. Finally, the product of the
centrifugal SHS reaction between Fe2O3and Al is a metalceramic
Al2O3Fe composite [6]. The post-processing of the ceramic-lay-
ered tubes may pose some disadvantages for the ceramic layer.
Various local reinforcement components such as titanium carbide
composites can assist in this regard.
Titanium carbide (TiC) has many desirable properties, among
which are high hardness, low density, high melting temperature,
high modulus, great corrosion resistance and excellent wetting
properties to Fe[7,8]. The application of TiC particulate has been
noted in wear resistant parts, thermal fatigue, erosion-resistant
materials, and high performance tooling. The most frequently re-
ported TiCFe composite is fabricated either by ex situ methods
like powder metallurgy or in situ in the medium of Fe [9,10]. TiC
is thermodynamically stable in steels, and thus provides fine rein-
forcement for wear resistant applications[11].
The TiC resulting from the reaction between Ti and C starting
powders is characterized by high hardness, good wettability, low
density, and chemical stability with the Fe-based matrix. In situ
functionally-graded materials (FGM) consisting of ceramic and
intermetallic components is appropriate for a number of post-pro-
cessing applications, such as piping branches and orifice nibs of
1359-8368/$ - see front matter 2013 Elsevier Ltd. All rights reserved.http://dx.doi.org/10.1016/j.compositesb.2013.12.016
Corresponding author at: Centre of Advanced Manufacturing and Materials
Processing (AMMP), Department of Mechanical Engineering, University of Malaya,
50603 Kuala Lumpur, Malaysia. Tel.: +60 (3)79675200; fax: +60 (3)79675330.
E-mail addresses: [email protected] (R. Mahmoodian), hamdi@
um.edu.my(M. Hamdi),[email protected](R.G. Rahbari).
Composites: Part B 59 (2014) 279284
Contents lists available at ScienceDirect
Composites: Part B
j o u r n a l h o m e p a g e : w w w . e l s e v i e r . c o m / l o c a t e / c o m p o s i t e s b
http://dx.doi.org/10.1016/j.compositesb.2013.12.016mailto:[email protected]:[email protected]:[email protected]:[email protected]://dx.doi.org/10.1016/j.compositesb.2013.12.016http://www.sciencedirect.com/science/journal/13598368http://www.elsevier.com/locate/compositesbhttp://www.elsevier.com/locate/compositesbhttp://www.sciencedirect.com/science/journal/13598368http://dx.doi.org/10.1016/j.compositesb.2013.12.016mailto:[email protected]:[email protected]:[email protected]:[email protected]://dx.doi.org/10.1016/j.compositesb.2013.12.016http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://crossmark.crossref.org/dialog/?doi=10.1016/j.compositesb.2013.12.016&domain=pdfhttp://-/?- -
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thick ceramic-coated pipes. It will enhance the inner-most layer of
the ceramic surface that undergoes mechanically damages and
crack propagation while transporting fluids or material. This would
prevent the ceramic surface of the pipe from eroding, corroding or
cracking excessively.
Ferro-TiC is a superwear cermet with good erosion resistance,
machinability and hardenable properties[12,13]. TiCFe cermet
has low soldering or brazing capabilities under atmospheric condi-
tions with large surfaces[14]. Therefore, ex situ TiCFe is not eco-
nomical when used as an insert in the case of ceramic-lined pipes.
A number of papers have been published on the synthesis of
TiC-reinforced Fe-based composites [1517]using different start-
ing materials under normal gravity conditions and with powder
metallurgy technique. The advantage of powder metallurgy is that
the products surface quality and precision are excellent; however,
production cost is high, while product shape and size are
restricted. For this reasons, several works on the liquid-based
means have been published in the past decade[18].
Gowtam et al. studied FeTiC steel FGM using SHS reaction fol-
lowed by centrifugal casting[19](Fe2O3, MnO2, and TiO2powders
in the presence of C), in situ TiC-reinforced steel composites[20],
cast-sintering [21], as well as spark plasma sintering [22] and
chemical vapor deposition [23]. In another study conducted by
Huang et al., TiCTiB2 ceramics were prepared via combustion syn-
thesis under a high gravity field[24]. Recently, Shi et al. reported a
processing and abrasive wear study of FeAl2O3TiC composite by
pressure-less Ti-activated reactive melt infiltration [25]. The pro-
duction of an in situ TiCFeAl2O3composite system under centrif-
ugal force utilized the heat generated by the highly exothermic
thermite reaction of Fe2O3 and Al, whereby the reaction of Ti and
C can be achieved at a rapid heating rates and short reaction times.
The adiabatic combustion temperatures of the SHS Fe2O3+ Al and
Ti + C reactions can reach 3622 C and 3290 C, respectively [19],
much higher than the melting point of Al and Fe2O3 [26]. The
advantage of this process is that once ignited, no further externally
applied energy is required to complete the reaction [27]. Al2O3
TiTiAl/Ti3Al processing using SHS is reported elsewhere but notunder centrifugal processing conditions[28,29]. So far, to the best
of the authors knowledge, no report has been put forth describing
the production of an in situ TiCFeAl2O3TiAl/Ti3Al composite
system under centrifugal force using Fe2O3, Al, Ti, and C as starting
materials. In this paper, the locally reinforced functionally graded
coating, and the intermetallic layers of the composite product
before and after immersion into a humid environment are
investigated.
2. Experimental procedure
2.1. Materials and methods
A centrifugal thermite (CT) machine was utilized to facilitate ra-
pid centrifugal acceleration as well as temperature increase during
the experiment. A bilayer graphitesteel compacted mold was
fixed inside the CT reaction chamber. A high performance infrared
thermometer, Raytek MM1MHSF3L, recorded the experimental
real-time temperature data. The detailed procedure of using the
centrifugal machine for thermite processing in metallic pipes is ex-
plained in recently published literature[4].
The starting materials, namely Al (
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only 2.5 s from ignition until Fe solidification, at which point it is
assumed that reaction and infiltration is stopped. The thermite
reaction products (Fe and Al2O3) deposited according to their den-
sities [32] at the graphite molds innermost layer, and then diffused
inside the TiC zone. The reactions created a porous TiC product.
The product formed, i.e. TiCFeAl2O3 composite, had a round,
rough innermost layer surface, and was microscopically porous
at the cross-section. The average roughness (Ra) value inFig. 2, re-
gion 4 (specimens face) was about 3.12 lm. The rapid heating andsuper-cooling process of the material would have caused surface
imperfections [33]. Increasing the amount of thermite mixture
fed into tube does not improve the innermost surface quality sig-
nificantly, since it is a rapid melting and cooling process. As for
FESEMEDAX analysis, an electron beam scanned along a pres-
elected line across the sample, while X-rays detected discrete posi-
tions along the line. Line analysis of the X-ray energy spectrum in
Fig. 2provides plotting of the relative elemental concentration for
each element versus position along the white line at the center of
the figure.
InFig. 2layer (1), TiC-rich area, there was only a small amount
of Al representing Al2O3 or Al intermetallic detected as well as a
high amount of Fe which penetrated the TiC zone. The intermetal-
lic compounds comprising Ti, Al and Fe were mostly located in
zone (2). All the starting elements participated in the experiments,
thus increasing the quality of joining properties to each other;
however, Fe was most uniformly distributed along area (2). The
products middle layer (2) and (3) contained the highest amount
of Al. The carbon content was diffused in all the layers, although
titanium was diffused inside the Al-rich layer (3). The elemental
composition of layer (4) was rich in Fe. The very weak signal in
layer (4) for C and Ti is noise. There are some imperfection
deposition happened since the pellet was situated at the head of
the pipe whereas the highest temperature gradient exists. The high
temperature gradient can cause the molten iron at the surrounding
area moving to the head and created an unexpected layer [33].
Therefore, the layer (4) mainly contains Fe.
A typical area of the products TiC zone is shown in Fig. 3 before
(a) and after (b) being exposed to environment where different
locations are highlighted based on EDAX elemental analysis. The
pores of TiC zone area seemed to be filled by the molten compos-
ite due to high centrifugal acceleration that acts as an external
force. At high gravity pressure the molten composite wet the cera-mic surface and filled the pores[34]. There are extensive reports of
molten metal capillary infiltrating a porous medium to form a
ceramic-metal composite[35].
Fig. 3(b) shows a micrograph image of the sample that was ex-
posed to environmental conditions and the corresponding EDAX
elemental analysis of different locations at points 1 and 2, and zone
3 are provided inTable 1. Various compounds were identified in
the sample including iron oxide, titanium oxide, and carbon-based
compounds such as TiC and Fe3C. According to the literature,
corrosion begins at high interfacial energy and relatively weak
bonding locations, such as grain boundaries[36].
A scaling issue was also encountered here that increased the
surface area. This phenomenon is similar to corrosion problems
are mostly the result of tuberculation [37]. The findings are compa-
rable to those of Tao et al. regarding the flower-like anatase TiO2hierarchical spheres assembled by nanosheets synthesized by gly-
cine via a hydrothermal approach[38]. Tao et al. claimed that the
obtained TiO2sample demonstrated good photocatalytic activity of
decomposing of methyl orange under sunlight [38]. The oxide layer
inFig. 3(b) is needle-like (flower-like) with sharp edges. This sort
of surface changes are significant with respect to tribological
behavior as they cause fretting corrosion damage in biomedical
applications [39]. According to EDAX results, the corroded area
consisted of FeO, Al2O3, TiO2, and TiC components after three-day
exposure to the environment. However, the SEM-EDAX analysis
inFig. 3(b) shows that points 1 and 2 contain very little oxygen
(
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X-ray diffraction pattern (XRD) of the whole specimens
cross-section elaborates the existing phases inFig. 4, and confirms
the formation of a polycrystalline product with different TiCFe
Al2O3 composite phases. The compounds intermetallic peaks of
tetragonal titanium aluminide (TiAl, Ti3Al) were detected in the
XRD pattern. The presence of intermetallic compounds enhances
crystal properties in the form of ordered crystal structures [40].
The Ti and Al atoms occupy specific locations in the crystal
structure rather than random locations as in the majority of solidsolutions. Intermetallics have been shown to possess lower ductil-
ity properties, with environmental factors also playing a role in
limiting ductility in intermetallics[36].
According to XRD and Rietveld refinement results, 28% of the
product was composed of TiC h11 1i, and h00 2i crystal direction
with cubic structure. Hexagonal titanium h01 1i, h01 0i crystal
direction 28.2% and hexagonal carbon h00 2i, h00 4i crystal
direction 23.0% elements did not react with each other but took
part in metallurgical alloying and joining.
2.5% of Al2.54Fe0.55Ti systemh02 2i crystal direction is formed.
The ternary iron [41] has a cubic structure, with a substantial capa-
bility of the developing intermetallic-based materials for high tem-
perature applications [42]. The AlFeTi alloy also has
ferromagnetism properties [43]. The XRD pattern did not display
a strong anatase peak, as this compound grew as a thin layer on
the top surface layer of the composite. It was not readily detectableby normal XRD, but was perceived by FESEM. Corundum (Al2O3),
wuestite (FeO), and Cohenite (Fe3C) were detected by XRD with
6.5%, 4.5%, and 2.2% quantity in the composite, respectively.
The relatively sharp peak (Ti, C) which represents the amount of
unreacted titanium and crystallized carbon may seem to be high
due to the XRD mechanism that scanned the whole area of the
samples cross-section from the inner-most layer up to the
Fig. 4. XRD diffraction pattern on cross-section of the specimen.
Fig. 5. Average Vickers hardness (HV) measurement of different typical point of TiC-rich zone (1), Fe-rich zone (2), versus TiC-rich and Fe-rich ( [33,44]), and TiCFe phase([15,45]).
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outer-most layer. Starting from the outer-most layer of the sample,
whereas the outer TiC pellet surface was not directly exposed to
the heat. On the other hand, the reaction time was too short to
propagate and transfer the generatedheat inside the pellet, and be-
sides, the intermetallic layers may have also prevented the rest of
the specimen from reacting. The importance of the intermetallic
layers is their support in providing a smooth transition of phases
and compounds over the volume of the product.The mechanical properties in terms of micro-hardness conform-
ing to Fig. 3(b) was measured in zones 1 and 2. The hardness
reading result are plotted in Fig. 5 versus the hardness of those
in literature [44,45]. The maximum Vickers hardness value
(2313 HV) was observed at a TiC-rich region, whereas the maxi-
mum hardness value of the less TiC-rich area was 1251 HV.
Whereas the hardness variation is an indication of phase transition
over the volume of the product [46].
Employing an in situ technique to produce net-shaped products
of the reinforcing ceramic-alloy composite with substantial inter-
metallic constitutes will reduce post-processing cost and increase
the service life of the manufactured parts significantly.
4. Conclusion
In the present study, the reaction temperature of the centrifugal
thermite-assisted combustion synthesis between Al and Fe2O3was
observed to be above 2925 C. According to FESEMEDAX TiO2were primarily formed after three days of exposure to a humid
environment due to product surface corrosion however it was
not detectable by XRD. In situ FGMs of TiCFeAl 2O3 with prede-
fined geometry and several intermetallics layers mainly TiAl and
Ti3Al with improved mechanical properties was successfully
produced.
Acknowledgements
This study has been supported by University of Malaya student
grant, Postgraduate Research Fund (PPP), Malaysia Ministry of
Higher Education (MOHE) and the High Impact Research-Joining
Technology (HIR-D00000116001). Special thanks to Mr. Ali
Mahmoodian, the CEO of Azarin Kar Ind. Co., for consulting and
facilitating the design and fabrication of the SHS-centrifugal
machines reaction chamber.
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