In-situ densification and combustion synthesis was investigated as a unique processing technique for the formation of carbon nanotube reinforced nickel aluminides. Nano-sized reactants were utilized to form NiAl-CNT composites with densities up to 96% of the theoretical and nanosized grains were observed. For composites synthesized with 1-wt% single-walled carbon nanotubes a 30 % improvement in Vickers microhardness was observed over the monolithic material. The same improvement was not observed for multi-walled carbon nanotubes. It is demonstrated that with increased carbon nanotube loading the reaction is critically impacted leading to pre-melting and hence low product density, and a reduction in Vickers microhardness.
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