Production of Cast Materials Based on the Cr2AlC MAX Phase by SHS Metallurgy Using Coupled Chemical Reactions

Abstract

It is known that materials based on MAX phases possess a large potential for use in aerospace, automobile, and industrial spheres because they have a unique combination of features of both metals and ceramics with high mechanical, chemical, thermal, and electrical properties. In this work, the experimental results of fabricating cast materials in the Cr–Al–C system with different ratios between the Cr2AlC MAX phase and chromium aluminides and carbides by SHS metallurgy are presented. The experiments were performed in an SHS reactor 3 L in volume at an initial inert gas (argon) pressure of 5 MPa. The synthesis was performed based on chemically coupled reactions: weakly exothermic (heat acceptor)—Cr2O3/3Al/C and strongly exothermic (heat donor)—3CaO2/2Al. The experimental results have good correlation with the preliminary thermodynamic calculations. It is shown that, when varying the composition of initial mixtures, it is possible to substantially affect the calculated and experimental synthesis parameters, as well as the phase composition and microstructure of final products. Optimal synthesis conditions of the material providing the maximal yield of the Cr2AlC phase in the ingot composition are established. The determining factor affecting the Cr2AlC content in the product is the occurrence time of the liquid phase under the synthesis conditions. It is shown that the maximal content of the Cr2AlC MAX phase and target product yield are attained at the 30% content of the strongly exothermic additive (3CaO2/2Al) in the initial charge.