Simulation of Self-Propagating High-Temperature Synthesis Using Finite Element Method

Abstract

Abstract Self-Propagating High-Temperature Synthesis (SHS) is an energy efficient process for the synthesis of refractory ceramics and intermetallic compounds, and composites of these materials including functionally gradient materials (FGMs). The process utilizes the large exothermic heat of reaction between two or more elements (or compounds) in order to convert the reactants into one or more useful products. The products of SHS, in general, have been observed to possess significant amounts of residual porosity. It has been reported that a certain amount of liquid phase during the reaction aids in the consolidation process. In order to control the amount of liquid formed during SHS, it is necessary to develop a good understanding of the parametric influence of the various process parameters such as pre-heat, dilution, heat losses, etc. on the SHS reaction. In this study, a commercial finite element program, ABAQUS (1996), has been used to simulate SHS and to study the effects of process parameters that influence and help control the reaction. Processing maps have been developed for Ni-Al system based on the FEA results that can aid in syntheses of nickel aluminides and FGMs using these compounds with low residual porosities.