Design of binder jet additive manufactured co-continuous ceramic-reinforced metal matrix composites

doi:10.1016/j.jmst.2020.01.053

Abstract

Abstract:

Ceramic-reinforced metal matrix composites (MMCs) display beneficial properties owing to their combination of ceramic and metal phases. However, the properties are highly dependent on the reinforcing phase composition, volume fraction and morphology. Continuous fiber or network reinforcement morphologies are difficult and expensive to manufacture, and the often-used discontinuous particle or whisker reinforcement morphologies result in less effective properties. Here, we demonstrate the formation of a co-continuous ceramic-reinforced metal matrix composite using solid-state processing. Binder jet additive manufacturing (BJAM) was used to print a nickel superalloy part followed by post-processing via reactive sintering to form a continuous carbide reinforcing phase at the particle boundaries. The kinetics of reinforcement formation are investigated in order to develop a relationship between reactive sintering time, temperature and powder composition on the reinforcing phase thickness and volume fraction. To evaluate performance, the wear resistance of the reinforced BJAM alloy 625 MMC was compared to unreinforced BJAM alloy 625, demonstrating a 64 % decrease in the specific wear rate under abrasive wear conditions.

Key words: Binder jetting, Reactive sintering, Metal matrix composite, Co-continuous composite, Wear resistance

Pablo D. Enrique, Ehsan Marzbanrad, Yahya Mahmoodkhani, Ali Keshavarzkermani, Hashem Al Momani, Ehsan Toyserkani, Norman Y. Zhou. Design of binder jet additive manufactured co-continuous ceramic-reinforced metal matrix composites[J]. J. Mater. Sci. Technol., 2020, 49: 81-90.

Figures/Tables 16

Fig. 1. Wear pin dimensions in mm for a) ZrO2 and b) Si3N4.

Fig. 2. SEM images of particles on surface of a) BJAM alloy 625, b) BJAM alloy 625 MMC, and EDX scans of the MMC surface showing c) Cr and d) Ni concentration.

Fig. 3. a) Back scatter SEM image of the cross-sectioned MMC and b) EDX line scan as indicated by the arrow.

Fig. 4. a) EBSD images of the cross-sectioned MMC showing a) a phase map, b) a kernel average misorientation map, and c) a crystal orientation inverse pole figure map.

Table 1 Comparison of compositions (wt%) excluding minor alloying elements.

Sample	Ni	Cr	Mo	Fe	Nb
Nominal alloy 625	>58	20-23	8-10	<5	3.15-4.15
Measured alloy 625	58.4	20.5	10.3	4.8	3.7
Depleted matrix	71.2 ± 0.6	7.4 ± 0.3	7.1 ± 0.6	5.8 ± 0.3	3.1 ± 0.3
Hastelloy N	71	7	16	<4	0

Fig. 5. SEM images of a Cr3C2 coating on a cast alloy 625 specimen after 3 h at 1200 °C showing a) the cross section of the coating and b) the top surface of the coating, compared to SEM images of c) a particle with a Cr3C2 shell and d) a magnified view of the shell using a backscatter detector.

Table 2 Fitted model parameters for Eq. (1) obtained from Fig. 6a.

Temperature [°C]	k [m² s^-1]	d₀ [m]	R²
1100	6.6 × 10^-16	0	0.99
1150	1.56 × 10^-15	0	0.99
1200	2.38 × 10^-15	2.72 × 10^-6	0.99

Fig. 6. a) Thickness of the Cr3C2 coating on cast alloy 625 as a function of time at various temperatures and b) an Arrhenius plot showing the logarithm of the growth rate constant as a function of the inverse temperature.

Table 3 Fitted model parameters for Eq. (2) obtained from Fig. 6b.

System	k₀ [m² s^-1]	E_a [kJ mol^-1]	R²
This study	1.2 × 10^-7	216	0.97

Fig. 7. EDX line scans of cast alloy 625 samples with zb60 coatings exposed to 1200 °C showing Cr depletion over time as a function of distance from the carbide-matrix interface.

Fig. 8. Cr3C2 growth during furnace ramp up (t<0) and at hold temperature of 1200 °C.

Fig. 9. Maximum Cr3C2 shell volume fraction achievable with varying Cr concentrations in the starting powder. Values for some Ni-based alloys and the current study’s MMC are shown, with adjustments (no-fill shapes) for Mo solubility in the Cr3C2 shell.

Fig. 10. Wear profiles using ZrO2 on a) BJAM alloy 625, b) BJAM alloy 625 MMC, and using Si3N4 on c) BJAM alloy 625 and d) BJAM alloy 625 MMC. Wear tracks are shown from e) conditions in (a), and f) conditions in (b).

Table 4 Specific wear rate (kw) in units of m2N-1.

Pin Material	(k_w1) BJAM alloy 625	(k_w2) BJAM MMC	k_w1/k_w2 ratio
ZrO₂	4.39E-12	1.42E-12	3.09:1
Si₃N₄	3.70E-12	1.49E-12	2.49:1

Fig. 11. a) Backscatter SEM image of the MMC after wear testing and b) SEM image of tilted MMC sample after wear testing.

Fig. 12. SEM image of MMC showing a) crack propagation in the Cr3C2 phase blunted by the Ni matrix and b) plastic deformation at the Ni-Cr3C2 interface.

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