Liquid-State Processing intrinsically stable because they are produced under near-equilibrium conditions and generally feature lowenergy

interphase boundaries. However, when exposed to temperature changes or gradients, coarsening occurs, that is, the rods tend to thicken and shorten, thus affecting the mechanical properties of the material. The mechanisms responsible for coarsening include oxidation and interfacial or bulk diffusion caused by a change in the solubility of the phases, and occur preferentially at grain boundaries or faults in the structure (Elliott 1983).

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field; the fibers become polarized and thus orient themselves along the field lines (Itoh et al. 1988; Masuda and Itoh 1989). For in-situ composites, remelting and directional solidification allows for alignment of the reinforcement in initially randomly oriented XD material (Kampe et al. 1990). Gradients in volume fraction reinforcement resulting from preform compression during infiltration, as mentioned in Section 1.1.1.3., can be minimized based on an understanding of the process governing phenomena. For example, if the compressive strength of the preform is known, pressure (or infiltration velocity) can be adjusted during the infiltration phase in order to avoid 1.4.2.2 Chemical Reactions preform compression,and then raised again later during In the case of in-situ composites produced by reaction solidification to obtain the desired microstructure between a liquid and other phases, such as gas or solid, (Booth et al. 1983). the governing mechanisms are those that are encounTo alter the often time-consuming and delicate stage tered in chemical reactions. Their elucidation involves of preform fabrication, several approaches have been identification of the possible reactions taking place and investigated. Foams constituting a three-dimensional evaluation of the driving force derived from thermody- network of ceramic have recently been used for liquidnamic considerations and reaction kinetics. These are metal infiltration (Figure 1-10)(Battelle Advanced Mafunctions of temperature and alloy, gas or solid compo- terials 1990; Fitzgerald and Mortensen 1992).Another sitions and concentrations, as well as diffusion mecha- type of three-dimensional network was proposed by nisms across reaction or boundary layers, as detailed for Lange in which slurries of alumina particles are infilexample, by Sahoo and Koczak (1991). Some of these trated into a pyrolizable phase and subsequently sinreactions are highly exothermic, including the XD pro- tered after pyrolization of the initial phase (Lange et al. cess (Marietta Laboratories, Baltimore, MD) (West- 1988). If loose fibers or particles are used, hybridization wood 1988; Meahanov 1990), and present the advan- allows the minimization of contact points and a reduction of the volume fraction. For example, coating contage of being fast and self-propagating. tinuous Sic fibers with a small amount of fine Sic particulates or whiskers prevents the loose fibers from 1.5 Optimization of Liquid-Metal Processing touching during infiltration. The resulting hybrid composites feature increased longitudinal and transverse strength (Feest et al. 1989; Towata and Yamada 1986). 1 . 5 . 1 Reinforcement In a similar fashion, adding some fibers when compactA number of problems associated with liquid-state pro- ing a particle preform allows for reduction of the cesses arise from the reinforcement; consequently, at- volume-fraction reinforcement because fibers do not tempts to improve processes need to include optimiza- pack as closely as particles (Friend et al. 1991).Another tion of the reinforcing-phase architecture and its behavior way to produce a particle-reinforced composite with a during combination with the metal. (Modification of the lower volume fraction combines infiltration and disperreinforcement surface.to improve wetting or alter reaction sion processes. A dense compact is first infiltrated under pressure, then diluted into liquid metal to achieve the mechanisms are addressed in Chapter 3.) In infiltration processes, a preform of the reinforcing desired volume-fraction reinforcement (Klier et al. phase is often prepared prior to infiltration, for example 1991). If well controlled, the inhomogeneity of the by dispersing the reinforcement in a solution containing reinforcement distribution can also be used to advanan inorganic binder, pressing to the desired volume tage: Al-reinforced alumina fibers or ceramic particles fraction, and drying the cake composed of fibers and composites have been produced by centrifugal casting residual binder material (Baty et al. 1987; Ebisawa et al. and feature increased wear resistance at the surface, 1991). When short fibers are used, fiber alignment is where it is most needed (Suery and LaJoye 1990; difficult to achieve, unless the composite is extruded, Tsunekawa et al. 1988). which generally damages the fibers. An innovative apIt seems, however, that a main obstacle to a wider use proach has been proposed by Itoh and coworkers to of many metal-matrix composite materials is the price solve this problem: a nonconductive fluid, containing of the reinforcement. Continuous fiber-reinforced comthe fibers and a surfactant, is subjected to a DC electric posites successfully compete with other materials only