Near‐Net‐Shape Processing of Metal‐Ceramic Composites by Reactive Metal Penetration

Abstract

Metal‐ceramic composites were made to near‐net shape by reacting phase‐pure mullite and mullite‐glass preforms with molten Al using a reactive metal penetration process. Conversion of the two ceramic preforms to Al 2 O 3 /Al composites was accompanied by a 0.32% volume expansion and a 1.42% volume shrinkage, respectively. Molar volume and density calculations made assuming a net‐shape reaction estimate ∼17 and ∼27 vol% Al to be present in the two composites after reaction. Results from quantitative stereology measurements used to quantify the concentration of metal in the reactively formed composites validate the calculations.