Optimization of Processing Parameter and Mechanical Response Analysis of Advanced Heterogeneous Laminated Composites Using Ni/Al Foils by In Situ Reaction Synthesis

Abstract

The advanced heterogeneous laminated composites were successfully fabricated by vacuum hot pressing using Ni and Al foils by in situ solid-state reaction synthesis. The effects of holding time and temperature on the microstructure and phase distribution were analyzed using scanning electron microscopy. Based on the optimized processing parameters, the microstructure and phase transformation, and the relationship between the microstructure and the corresponding mechanical properties were discussed in detail. To clarify the mechanical response of the laminated structure, the deformation microstructure and fracture characteristics were studied by scanning electron microscopy and electron backscatter diffraction. The results indicated that the evolution of the interfacial phases in the laminated composite occurred via the sequence: NiAl3, Ni2Al3, NiAl, and Ni3Al. An interface between the Ni and Ni3Al layers without cracks and voids formed due to the uniform pressure applied during hot pressing. The laminated composites hot pressed under 620 °C/5 MPa/1 h + 1150 °C/10 MPa/2 h exhibited the best ultimate tensile strength of 965 MPa and an elongation of 22.6% at room temperature. Extending the holding time during the second stage of the reaction synthesis decreased the thickness of the Ni3Al layer. This decreased the tensile strength of the laminated composite at 1000 °C but improved the tensile strength at room temperature. Moreover, the layer–thickness relationship of the laminated structure and the matching pattern were important factors affecting the strength and elongation of the laminated composites. The reinforcement form of the materials was not limited to a lamellar structure but could be combined with different forms of reinforcement to achieve continuous reinforcement over a wide range of temperatures.