Recent progress in additive manufacturing of bulk MAX phase components: A review

doi:10.1016/j.jmst.2022.05.026

Abstract

Abstract:

The MAX phases are a group of layered ternary, quaternary, or quinary compounds with characteristics of both metals and ceramics. Over recent decades, the synthesis of bulk MAX phase parts for wider engineering applications has gained increasing attention in aerospace, nuclear, and defence industries. The recent adoption of additive manufacturing (AM) technologies in MAX phase fabrication is a step forward in this field. This work overviews the recent progress in additive manufacturing (AM) of bulk MAX phases along with the achieved geometric features, microstructures, and properties after briefing the conventional powder sintering methods of fabricating MAX phase components. Critical challenges associated with these innovative AM-based methods, including, poor AM processability, low MAX phase purity, and insufficient geometric accuracy of the final parts, are also discussed. Accordingly, outlooks for the immediate future in this area are discussed based on the optimization of present fabrication routes and the potential of other AM technologies.

Key words: MAX phase, Binder jetting, Direct-ink-writing, Sheet lamination, Sintering

Qiyang Tan, Wyman Zhuang, Marco Attia, Richard Djugum, Mingxing Zhang. Recent progress in additive manufacturing of bulk MAX phase components: A review[J]. J. Mater. Sci. Technol., 2022, 131: 30-47.

Figures/Tables 15

Fig. 1. Schematic representing the crystal structure of Mn+1AXn phases.

Table 1. The known Mn+1AXn phases, sorted by stoichiometry (“211”, “312”, “413”, “514”, “615” and “716”) [18], [19], [20],[29], [30], [31], [32].

Category	Compound
211	Sc₂InC, Ti₂CdC, Sc₂SnC, Ti₂AuN, Ti₂GaC, Ti₂AlC, Ti₂InC, V₂AlC, Ti₂TlC, V₂GaC, Ti₂AlN, Cr₂GaC, Ti₂InN, Ti₂GaN, Cr₂GaN, V₂GaN, Ti₂GeC, Ti₂PbC, Ti₂SnC, V₂GeC, Cr₂GeC, V₂PC, Cr₂AlC, V₂AsC, Zr₂InC, Ti₂SC, Zr₂TlC, Nb₂GaC, Nb₂AlC, Nb₂InC, Zr₂InN, Mo₂GaC, Zr₂TlN, Zr₂PbC, Zr₂SnC, Nb₂SnC, Nb₂AsC, Nb₂PC, Zr₂SC, Hf₂InC, Nb₂SC, Hf₂TlC, Ta₂GaC, Ta₂AlC, Hf₂SnC, Hf₂SnN, Hf₂PbC, Hf₂SC, Ti₂ZnC, Zr₂AlC, Ti₂ZnN, Nb₂CuC, V₂ZnC, Mn₂GaC, Mo₂AuC, (Zr, Nb)₂(Al, Sn)C, V₂SnC, Nb₂SB, Zr₂SB, Hf₂Sb
312	Ti₃AlC₂, Ti₃InC₂, Ti₃GaC₂, V₃AlC₂, Ti₃GeC₂, Ti₃SiC₂, Ti₃SnC₂, Ti₃ZnC₂, Ta₃AlC₂, Zr₃AlC₂
413	Ti₄AlN₃, Ti₄GaC₃, V₄AlC₃, Ti₄SiC₃, Nb₄AlC₃, Ti₄GeC₃, (Mo,V)₄AlC₃, Ta₄AlC₃,
514	(Ti_0.5Nb_0.5)₅AlC₄, Mo₄VAlC₄, Ti₅Al₂C3
615	Ta₆AlC₅
716	Ti₇SnC₆

Fig. 2. SEM micrographs of HP-sintered MAX phases: (a) Ti3SiC2 and (b) higher-magnification micrograph marked in (a), showing the striated Ti3SiC2 grain; (c) Ti2AlC, with the inset showing the magnified view of the striated Ti2AlC grains; (d) Cr2AlC. Reprinted from Barsoum and El-Raghy [65], Cai et al. [68], and Zhu et al. [69].

Fig. 3. Properties of some sintered 211 and 312 MAX phases: (a) density, (b) electrical conductivity, (c) thermal conductivity, (d) hardness, (e) fracture toughness, and (f) compressive strength [84], [85], [86], [87], [88], [89], [90], [91], [92], with the grid patterns in (d) and (e) representing the value variations.

Fig. 4. Conceptual image of binder jetting, reproduced from Oropeza and Hart [47].

Fig. 5. Parts morphology at (a) as-printed condition, (b) printed followed by CIP, and (c) printed followed by CIP and sintering, reproduced from Sun et al. [122].

Fig. 6. Microstructural characterization of Ti3SiC2 compound fabricated with the binder jetting-consolidation route: (a) optical micrograph and (b) higher magnification SEM image of the sample fabricated by binder jetting/CIP/Sintering, reproduced from Dcosta et al. [127]; (c) SEM micrograph of the sample fabricated through binder jetting with TiC powder followed by liquid silicon infiltration, reproduced from Nan et al. [118].

Table 2. Properties of MAX phases fabricated by sintering and binder jetting fabrication routes. σf is the flexural strength, ρr denotes the relative density, H is the hardness, σc is the compressive strength, KIC represents the fracture toughness, E is the Young's modulus, and ρ0 is the electrical resistivity.

MAX phases	Method	σ_f (MPa)	ρ_r (%)	H (GPa)	σ_c (MPa)	K_IC (MPa m^1/2)	E (GPa)	ρ₀ (µΩ m)	Refs.
Ti₃SiC₂	Conventional sintering	260-600	≥ 99	4	580-1050	6.2-16	322	0.23	[11,48,84]
	Binder jetting/CIP/sintering	390	90	9	1200	-	-	-	[127]
	Binder jetting/pressing/sintering	3000	98.3	-	-	-	286	-	[119]
	Binder jetting /RMI	293	97.6	7.2	-	4.56	-	0.28	[118,134]
Ti₃AlC₂	Conventional sintering	340-375	≥ 99	3.5	545-760	6.4-9.5	297	0.39	[48,67,84]
Ti₃AlC₂	Binder jetting /sintering/RMI	320	≥ 98.3	2.5	-	8.1-9.7	184	-	[120,128]

Fig. 7. Phase contents of the binder jetting/RMI-fabricated Ti3SiC2 sample with respect to the Si content in the RMI process, reproduced from Nan et al. [118].

Fig. 8. (a) Gearwheel CAD model (left) and the binder jetting/sintering/RMI fabricated Ti3AlC2 gearwheel (right), with the dashed circles showing the locations with sharp profiles. (b) SEM micrograph of the Ti3AlC2 sample. Reproduced from Yin et al. [128].

Fig. 9. Schematic diagrams of the fabrication mechanisms of (a) direct-ink-writing and (b) sheet lamination. Reproduced from Solís Pinargote et al. [136].

Fig. 10. Images of the as-printed lattice scaffolds (a) Cr2AlC and (b) Ti2AlC lattice scaffolds; SEM image of top views and cross-sections of the struts in (c, d) Cr2AlC lattice and (e, f) Ti2AlC lattice; cross-sectional SEM micrographs of (g) Cr2AlC strut and (h) Ti2AlC strut. Reproduced from Belmonte et al. [45] and Elsayed et al. [44].

Fig. 11. (a) Comparison of the compressive strength of the 3D-printed (direct-ink-writing/sintering) Cr2AlC and Ti2AlC lattices with the sintered porous MAX phase (solid symbols) and other 3D-printed porous ceramics (hollow symbols) [147], [148], [149], [150], [151], [152], [153], [154], [155], [156]. (b) Images of the Cr2AlC lattices before (left) and after (right) 200 thermal cycles at 1100 °C. (c) SEM image (top-view) of the Cr2AlC struts after the thermal cycling, showing excellent thermal shock resistivity and oxidation resistance at high temperature. Reproduced from Belmonte et al. [45].

Fig. 12. (a) Image of the 3D gear part produced by the fabrication route consisting of sheet lamination, sintering, and RMI, using the mixture of TiC and SiC at the ratio of 30:70 (vol.%) as the feedstock tape. (b-d) SEM micrographs of the final parts fabricated with different TiC to SiC ratios, (b) 30:70 (vol.%), (c) 50:50 (vol.%), and (d) 70:30 (vol.%). Reproduced from Krinitcyn et al. [46].

Fig. 13. Conceptual images of (a) PBF and (b) DED systems; representative examples showing the components fabricated by powder fusion AM techniques: (c) Ti-22Al-25Nb intermetallic with the shape of the turbine blade, reproduced from Zhou et al. [163], (d) Al2O3 with 3D complex shapes, reproduced from Juste et al. [164], (e) ZrO2-Al2O3 ceramic with the shape of the turbine in turbocharger, reproduced from Wilkes et al. [165].

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