Pack Aluminization Synthesis of Superalloy 3D Woven and 3D Braided Structures

Dinc Erdeniz*, Amanda J. Levinson, Keith W. Sharp, David J. Rowenhorst, Richard W. Fonda, David C Dunand

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

14 Scopus citations


Micro-architectured, precipitation-strengthened structures were created in a new process combining weaving, gas-phase alloying, diffusion, and precipitation. First, high-ductility Ni-20 wt pct Cr wires with 202 μm diameter were braided, or non-crimp orthogonal woven, into three-dimensional structures. Second, these structures were vapor-phase alloyed with Al at 1273 K (1000 °C) by pack cementation, creating uniform NiAl coatings on the wires when using a retort. Also, solid-state bonding was achieved at wire intersections, where two wires were sufficiently close to each other, as determined via optical and X-ray tomographic microscopy. Third, the NiAl-coated wires were fully homogenized and aged to form γ′ precipitates distributed in a γ matrix phase, the same microstructure providing strength in nickel-based superalloys. The resulting structures—consisting of wires (i) woven in a controlled three-dimensional architecture, (ii) bonded at contact points and (iii) strengthened by γ′ precipitates—are expected to show high strength at ambient and elevated temperatures, low density, and high permeability which is useful for active cooling.

Original languageEnglish (US)
Pages (from-to)426-438
Number of pages13
JournalMetallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Issue number1
StatePublished - Jan 1 2015

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys

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