Characterization and Integrated Fabrication of Al Components with Thick TiCp/Al Composite Coatings via Self-Propagating Reaction

Abstract

A novel and quick process combining self-propagating reaction with vacuum-expendable pattern casting is presented to accomplish integrated preparation of millimeter-thick TiCp/Al composite coatings on the Al substrate. Titanium and graphite powders were mixed with the polytetrafluoroethylene (PTFE) additive and pasted on the expendable polystyrene (EPS) followed by compaction. Al components with in situ TiCp/Al composite coating were simultaneously synthesized at a relatively low temperature of molten Al, which was poured into the assembly of EPS and powder compact inside the silica sands. Differential scanning calorimetry, x-ray diffraction, scanning electron microscopy with energy-dispersive spectroscopy and transmission electron microscopy were used to systematically investigate the thermodynamic characteristics of the reaction, the phase constituents, microstructure and tribological properties of the coatings. The infiltration model describing the densification of the reaction coatings was also developed for the critical wetting condition. The wear characteristics were assessed using a pin-on-disk tribometer with various loads. Results showed that uniform TiC particles stimulated by the PTFE-activated self-propagating reaction afforded superior mechanical properties and wear resistance.