In situ combustion synthesis of dense ceramic and ceramic-metal interpenetrating phase composites

A model exothermic reaction is used to demonstrate the application of simultaneous combustion synthesis, conducted under a consolidating pressure, as a one-step in situ synthesis technique for the production of dense ceramic and ceramic-metal interpenetrating phase composites (IPC). The addition of an excess amount of metal, e.g., Al, and/or a diluent, e.g., Al2O3, lowers the combustion temperature and aids in the refinement of the microstructure, facilitating an increase in compressive strength and elastic modulus. The effects of the important process parameters, e.g., reaction stoichiometry and diluents, green density, pressure, and temperature, on microstructure and properties of these high-performance composites are discussed.