Abstract
Owing to their outstanding strength, resistance to thermal shock and ablation, high thermal stability, and good thermal expansion, composites of tungsten with zirconium carbide (W/ZrC) have attracted great attention for high-temperature applications. Various techniques can be used for the production of W/ZrC composites, including hot-pressing, spark plasma sintering, in-situ reaction sintering, and displacive compensation of porosity. Both hot-pressing and spark plasma sintering are typically used for preparing small-sized samples with simple geometry. Both in-situ reactive sintering and reactive infiltration methods are well-suited to produce refractory metal/ carbide composites. The reactive infiltration method benefits from a thorough infiltration step because of the good wettability of WC by low-melting metallic liquid of Zr2Cu in a preform to produce a near net-shaped W/ZrC composite. The reaction of zirconium carbide with oxygen can enhance oxidation resistance through the formation of ZrO2 layer which can be melted at a higher temperature (2677 ℃), covering the surface to avoid further oxidation of substrates. Several methods have been reported to deposit the composite on complex-shaped substrates. The results showed good adhesion between coating and graphite substrates as well as a considerable increase in mechanical properties resulting from the formation of solid solution in composites. In this chapter, an attempt has been made to review the preparation of WC preforms which are mainly based on the polymerization of low-toxic methacrylamide and gelation of non-toxic sodium alginate to prepare porous preforms with complex geometries and summarize the preparation methods of W/ZrC composites using reactive sintering and infiltration methods, focusing on microstructures, mechanical properties, and progress in coating applications.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Abbreviations
- ANOVA:
-
Analysis of variance
- APS:
-
Ammonium persulfate
- BSE:
-
Backscattered electron
- CVD:
-
Chemical vapor deposition
- DCP:
-
Displacive compensation of porosity
- HP:
-
Hot pressing
- MAM:
-
Methacrylamide
- MBAM:
-
N,N′-Methylene bisacrylamide
- ORN:
-
Oak Ridge National Laboratory
- RMs:
-
Refractory metals
- SAD:
-
Selected area diffraction
- SEM:
-
Scanning electron microscopy
- SPS:
-
Spark Plasma Sintering
- TEM:
-
Trasmision electron microscopy
- TEMED:
-
N,N,N,N′-Tetramethylethylenediamine
- TIG:
-
Tungsten inert gas
- W:
-
Tungsten
- WC:
-
Tungsten carbide
- ZrC:
-
Zirconium carbide
References
Dickerson, M.B., Snyder, R.L., Sandhage, K.H.: Dense, near net-shaped, carbide/refractory metal composites at modest temperatures by the displacive compensation of porosity (DCP) method. J. Am. Ceram. Soc. 85, 730–732 (2002). https://doi.org/10.1111/J.1151-2916.2002.TB00164.X
Zhao, Y.W., Wang, Y.J., Chen, L., Zhou, Y., Song, G.M., Li, J.P.: Microstructure and mechanical properties of ZrCW matrix composite prepared by reactive infiltration at 1300 ℃. Int. J. Refract. Metals Hard Mater. 37, 40–44 (2013). https://doi.org/10.1016/J.IJRMHM.2012.10.014
Song, G.M., Wang, Y.J., Zhou, Y.: Elevated temperature ablation resistance and thermophysical properties of tungsten matrix composites reinforced with ZrC particles. J. Mater. Sci. 36, 4625–4631 (2001). https://doi.org/10.1023/A:1017989913219/METRICS
Roosta, M., Baharvandi, H.: The comparison of W/Cu and W/ZrC composites fabricated through hot-press. Int. J. Refract. Metals Hard Mater. 28, 587–592 (2010). https://doi.org/10.1016/J.IJRMHM.2010.04.006
Zhang, S.C., Hilmas, G.E., Fahrenholtz, W.G.: Zirconium carbide-tungsten cermets prepared by in situ reaction sintering. J. Am. Ceram. Soc. 90, 2296–2296 (2007). https://doi.org/10.1111/J.1551-2916.2007.01883.X
Najafzadeh Khoee, A.A., Habibolahzadeh, A., Qods, F., Baharvandi, H.: Microstructure and properties of DCP-derived W-ZrC composite using nontoxic sodium alginate to fabricate WC preform. J. Mater. Eng. Perform. 24, 1641–1648 (2015). https://doi.org/10.1007/s11665-015-1427-z
Mudanyi, R.K., Cramer, C.L., Elliott, A.M., Kumar, D.: Effect of W and C addition on the microstructure and phase composition of W-ZrC composites prepared by using Zr2Cu alloy and variant reactant compositions. Open Ceramics. 12 (2022). https://doi.org/10.1016/J.OCERAM.2022.100305
Dickerson, M.B., Wurm, P.J., Schorr, J.R., Huffman, W.P., Wapner, P.G., Sandhage, K.H.: Near net-shape, ultra-high melting, recession-resistant ZrC/W-based rocket nozzle liners via the displacive compensation of porosity (DCP) method. J. Mater. Sci. 39, 6005–6015 (2004). https://doi.org/10.1023/B:JMSC.0000041697.67626.46/METRICS
Zhao, Y., Wang, Y., Zhou, Y., Shen, P.: Reactive wetting and infiltration of polycrystalline WC by molten Zr2Cu alloy. Scr. Mater. 64, 229–232 (2011). https://doi.org/10.1016/J.SCRIPTAMAT.2010.10.018
Omatete, O.O., Janney, M.A., Nunn, S.D.: Gelcasting: from laboratory development toward industrial production. J. Eur. Ceram. Soc. 17, 407–413 (1997). https://doi.org/10.1016/S0955-2219(96)00147-1
Najafzadeh Khoee, A.A., Habibolahzadeh, A., Qods, F., Baharvandi, H.: Fabrication of tungsten carbide foam through gel-casting process using nontoxic sodium alginate. Int. J. Refract. Metals Hard Mater. 43, 115–120 (2014). https://doi.org/10.1016/j.ijrmhm.2013.11.011
Mouazer, R., Thijs, I., Mullens, S., Luyten, J.: SiC foams produced by gelcasting: synthesis and characterization. Adv. Eng. Mater. 6, 340–343 (2004). https://doi.org/10.1002/ADEM.200400009
Jin, Y., Zhang, B., Ye, F., Zhang, H., Zhong, Z., Liu, Q., Zhang, Z.: Development of ethylene glycol-based gelcasting for the preparation of highly porous SiC ceramics. Ceram. Int. 46, 7896–7902 (2020). https://doi.org/10.1016/J.CERAMINT.2019.12.009
Zhang, T., Zhang, Z., Zhang, J., Jiang, D., Lin, Q.: Preparation of SiC ceramics by aqueous gelcasting and pressureless sintering. Mater. Sci. Eng. A 443, 257–261 (2007). https://doi.org/10.1016/J.MSEA.2006.08.047
Xie, R., Zhang, D., Zhang, X., Zhou, K., Button, T.W.: Gelcasting of alumina ceramics with improved green strength. Ceram. Int. 38, 6923–6926 (2012). https://doi.org/10.1016/J.CERAMINT.2012.05.027
Prabhakaran, K., Pavithran, C.: Gelcasting of alumina using urea-formaldehyde II. Gelation Ceram. Form., Ceram Int. 26, 67–71 (2000). https://doi.org/10.1016/S0272-8842(99)00020-6
Studart, A.R., Gonzenbach, U.T., Tervoort, E., Gauckler, L.J.: Processing routes to macroporous ceramics: a review. J. Am. Ceram. Soc. 89, 1771–1789 (2006). https://doi.org/10.1111/J.1551-2916.2006.01044.X
Askari, S.R., Khakzadi, M., Shahpasandi, A., Najafzadehkhoee, A.: Fabrication of W-ZrC nanocomposite through reaction sintering using relatively low-toxic methacrylamide-based system. Compos. Commun. 13, 156–161 (2019). https://doi.org/10.1016/j.coco.2019.04.009
Finhana, I.C., Machado, V.V.S., Santos, T., Borges, O.H., Salvini, V.R., Pandolfelli, V.C.: Direct foaming of macroporous ceramics containing colloidal alumina. Ceram. Int. 47, 15237–15244 (2021). https://doi.org/10.1016/J.CERAMINT.2021.02.086
Deng, X., Wang, J., Huang, Z., Zhao, W., Li, F., Zhang, H.: Research progress in preparation of porous ceramics. InterCeram: Int. Ceram. Rev. 64, 100–103 (2015). https://doi.org/10.1007/BF03401108/METRICS
Montanaro, L., Coppola, B., Palmero, P., Tulliani, J.M.: A review on aqueous gelcasting: a versatile and low-toxic technique to shape ceramics. Ceram. Int. 45, 9653–9673 (2019). https://doi.org/10.1016/J.CERAMINT.2018.12.079
Eom, J.H., Kim, Y.W., Raju, S.: Processing and properties of macroporous silicon carbide ceramics: a review. J. Asian Ceram. Soc. 1, 220–242 (2013). https://doi.org/10.1016/J.JASCER.2013.07.003
Binner, J.G.P.: Production and properties of low density engineering ceramic foams. Br. Ceram. Trans. 96, 247–249 (1997)
Yaghobizadeh, O., Baharvandi, H., Alizadeh, A.: Investigation of effect of acrylate gel maker parameters on properties of WC preforms for the production of W-ZrC composite. Int. J. Refract. Metals Hard Mater. 45, 130–136 (2014). https://doi.org/10.1016/J.IJRMHM.2014.04.007
Wang, X., Xie, Z.P., Huang, Y., Cheng, Y.B.: Gelcasting of silicon carbide based on gelation of sodium alginate. Ceram. Int. 28, 865–871 (2002). https://doi.org/10.1016/S0272-8842(02)00066-4
Akhondi, H., Taheri-Nassaj, E., Sarpoolaky, H., Taavoni-Gilan, A.: Gelcasting of alumina nanopowders based on gelation of sodium alginate. Ceram. Int. 35, 1033–1037 (2009). https://doi.org/10.1016/J.CERAMINT.2008.04.023
Yang, J., Yu, J., Huang, Y.: Recent developments in gelcasting of ceramics. J. Eur. Ceram. Soc. 31, 2569–2591 (2011). https://doi.org/10.1016/J.JEURCERAMSOC.2010.12.035
Najafzadeh Khoee, A.A., Habibolahzadeh, A., Qods, F., Baharvandi, H.: Study on rheological behavior of WC slurry in gel-casting process and reactive infiltration of produced foam by molten Zr2Cu alloy. Int. J. Refract Metals Hard Mater. 46, 30–34 (2014). https://doi.org/10.1016/j.ijrmhm.2014.05.006
Schilling, C.H., Li, C., Tomasik, P., Kim, J.C.: The rheology of alumina suspensions: influence of polysaccharides. J. Eur. Ceram. Soc. 22, 923–931 (2002). https://doi.org/10.1016/S0955-2219(01)00394-6
Vitali, S., Giorgini, L.: Overview of the rheological behaviour of ceramic slurries, (n.d.). https://doi.org/10.5937/fmet1901042V
Yu, Z., Huang, Y., Wang, C.A., Ouyang, S.: A novel gel tape casting process based on gelation of sodium alginate. Ceram. Int. 30, 503–507 (2004). https://doi.org/10.1016/J.CERAMINT.2003.08.003
Trunec, M., Stastny, P., Kastyl, J.: Defect-free drying of large fine-particle zirconia compacts prepared by gelcasting method. J. Eur. Ceram. Soc. 42, 7180–7186 (2022). https://doi.org/10.1016/J.JEURCERAMSOC.2022.08.011
Li, X., Jiang, D., Zhang, J., Lin, Q., Chen, Z., Huang, Z.: The dispersion of boron carbide powder in aqueous media. J. Eur. Ceram. Soc. 33, 1655–1663 (2013). https://doi.org/10.1016/J.JEURCERAMSOC.2013.02.001
Dong, B., Wang, L., Min, Z., Wang, Q., Yin, C., Jia, T., Wang, Y., Zheng, X., Wang, F., Abadikhah, H., Xu, X., Zhang, Y., Wang, G.: Fabrication of novel porous Al2O3 substrates by combining emulsion templating and gel-tape-casting methods. Ceram. Int. 48, 7320–7324 (2022). https://doi.org/10.1016/J.CERAMINT.2021.11.205
Kim, J.H., Zhe, G., Lim, J., Park, C., Kang, S.: Thermodynamic stability of in situ W-ZrC and W-Zr(CN) composites. J. Alloys Compd. 647, 1048–1053 (2015). https://doi.org/10.1016/J.JALLCOM.2015.06.117
Oishi, T., Hirata, A., Ishida, H., Ono, K.: Outokumpu HSC chemistry for windows, chemical reaction and equilibrium software with extensive ther-mochemical. Database 64, 662–668 (1994). https://doi.org/10.2320/JINSTMET1952.64.8_662
Najafzadehkhoee, A., Habibolahzadeh, A., Qods, F., Vakhshouri, M., Polkowski, W., Hvizdos, P., Galusek, D., Sk, A.N.: Effect of ZrC nanopowder addition in WC preforms on microstructure and properties of W-ZrC composites prepared by the displacive compensation of porosity (DCP) method. J. Aust. Ceram. Soc. 57, 515–523 (2021). https://doi.org/10.1007/s41779-020-00538-1/Published
Najafzadehkhoee, A., Habibolahzadeh, A., Qods, F., Hvizdos, P.: A Taguchi approach to the influence of infiltration parameters on microstructure and properties of W-ZrC composites prepared by the displacive compensation of porosity (DCP) method. Compos. Commun. 20 (2020). https://doi.org/10.1016/j.coco.2020.05.002
Adabi, M., Amadeh, A.: Effect of infiltration parameters on composition of W-ZrC composites produced by displacive compensation of porosity (DCP) method. Int. J. Refract. Metals Hard Mater. 29, 31–37 (2011). https://doi.org/10.1016/J.IJRMHM.2010.06.009
Golestani Fard, M.A., Baharvandi, H.: Development of W-ZrC composite coating on graphite by a TIG-aided surface cladding process. Ceram. Int. 47, 27958–27971 (2021). https://doi.org/10.1016/j.ceramint.2021.06.227
Windhorst, T., Blount, G.: Carbon–carbon composites: a summary of recent developments and applications. Mater. Des. 18, 11–15 (1997). https://doi.org/10.1016/S0261-3069(97)00024-1
Lee, Y.J., Joo, H.J.: Ablation characteristics of carbon fiber reinforced carbon (CFRC) composites in the presence of silicon carbide (SiC) coating. Surf. Coat. Technol. 180–181, 286–289 (2004). https://doi.org/10.1016/j.surfcoat.2003.10.071
Li, Y., Liu, Y., Guo, C., Chen, Y., Liang, J., Zhang, J., Zhang, J., Guo, L.: Ablation resistance of ZrC-based composite coating with multi-layer structure for carbon/carbon composites above 2200 ℃. Corros. Sci.. Sci. 207, 110600 (2022). https://doi.org/10.1016/J.CORSCI.2022.110600
Yang, X., Huang, Q., Su, Z., Chang, X., Chai, L., Liu, C., Xue, L., Huang, D.: Resistance to oxidation and ablation of SiC coating on graphite prepared by chemical vapor reaction. Corros. Sci.. Sci. 75, 16–27 (2013). https://doi.org/10.1016/J.CORSCI.2013.05.009
Wen, G., Sui, S.H., Song, L., Wang, X.Y., Xia, L.: Formation of ZrC ablation protective coatings on carbon material by tungsten inert gas cladding technique. Corros. Sci.. Sci. 52, 3018–3022 (2010). https://doi.org/10.1016/J.CORSCI.2010.05.015
Acknowledgements
This research work has been supported by the Research Agency of the Ministry of Education, Science, Research and Sport of the Slovak Republic, by the project: Advancement and support of R&D for “Centre for diagnostics and quality testing of materials” in the domains of the RIS3 SK specialization, Acronym: CEDITEK II., ITMS2014+ code 313011W442.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this chapter
Cite this chapter
Najafzadehkhoee, A., Vakhshouri, M., Hvizdoš, P., Galusek, D. (2024). High-Temperature W/ZrC Composite Coatings. In: Pakseresht, A., Amirtharaj Mosas, K.K. (eds) Ceramic Coatings for High-Temperature Environments. Engineering Materials. Springer, Cham. https://doi.org/10.1007/978-3-031-40809-0_15
Download citation
DOI: https://doi.org/10.1007/978-3-031-40809-0_15
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-40808-3
Online ISBN: 978-3-031-40809-0
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)