Pressure Infiltration Processing of Reinforced Superalloys and Intermetalics

Five innovations are offered: 1) Pressure in filtration casting of net-shaped components with sapphire reinforced NiA1 and alumina multifilament tow reinforced In 718 superalloy, 2) low cost tooling concepts, 3) exact geometric positioning of fibers during processing, 4) the elimination or reduction of CTE mismatch strains between fibers and matrix during thermal cycling, and 5) defect free castings through controlled solidification. The principal Phase I objective is to prove the pressure infiltration of high temperature superalloy and inter- metallic composite concept. Experimentally, we will develop casting processes, and in doing so, we will examine the compatibility of various hybridization particulate candidates, mold, fiber coating and mold coating materials with NiAl and In 718. We will manufacture flexure and CTE specimens for the evaluation of ambient and high temperature flexure strength, CTE, and thermal cycling behavior. The following results are expected: Through use of hybridization, we will 1) achieve exact positioning of fibers in the preform and subsequent casting, 2) reduce CTE mismatch strains to tolerable levels and eliminate radial and longitudinal cracking, and 3) demonstrate a low cost process for the manufacture of low defect, high integrity, high performance, net shaped components.