It has been shown by the present author that when molten aluminum comes in contact with nickel, an exothermic reaction is initiated and both stiochiometric and non-stiochiometric phases form at the interface. For nickel powders, such reaction is expected to be much faster due to high surface area to volume ratio of the fine particles. Infiltration of molten metals in ceramics powder preforms has long been used to fabricate near or net-shaped Metal Matrix Composite components. For metallic preforms however, it is important to see if the exothermic reaction compromises the infiltration of the molten metal constituent, i.e. defective components. The current project studied the fabrication of near net-shaped Intermetallic Matrix Composites, (IMC) via molten metal infiltration and subsequent reaction with the metal powder preform. X-ray diffraction (XRD), Optical and SEM microscopes were used to characterize the infiltration, reaction and the resulted microstructure. It is expected that the molten metal temperature, holding time within the molten metal, the infiltration pressure, i.e. metallostatic pressure and the preform compaction pressure are all important parameters to be considered carefully to achieve sound components. The current report examined the feasibility of such fabrication technique and the resultant microstructure.
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