A novel technique is proposed and demonstrated for processing interpenetrating ceramic-metal composites by the infiltration of molten metals/alloys into ceramic foams utilizing a current-activated, pressure-assisted technique. Ti 2 AlC foams were prepared and used as the infiltration preform. Aluminum alloy 6061 (AA6061) has been infiltrated into the Ti 2 AlC foams, resulting in AA6061/Ti 2 AlC composites. The microstructure, composition, and distribution of phases in the composites were studied. The AA6061/Ti 2 AlC composites were studied under compression testing, and the results were compared with those of the pure components of the composites. Advantages of this method in comparison to other methods for processing metal-ceramic composites are discussed.

The prospect of extending existing metal-ceramic composites to those with the compositions that are far from thermodynamic equilibrium is examined. A current and pressure-assisted, rapid infiltration is proposed to fabricate composites, consisting of reactive metallic and ceramic phases with controlled microstructure and tunable properties. An aluminum (Al) alloy/Ti2AlC composite is selected as an example of the far-from-equilibrium systems to fabricate, because Ti2AlC exists only in a narrow region of the Ti-Al-C phase diagram and readily reacts with Al. This kind of reactive systems challenges conventional methods for successfully processing corresponding metal-ceramic composites. Al alloy/Ti2AlC composites with controlled microstructures, various volume ratios of constituents (40/60 and 27/73) and metallic phase sizes (42–83 μm, 77–276 μm, and 167–545 μm), are obtained using the Ti2AlC foams with different pore structures as preforms for molten metal (Al alloy) infiltration. The resulting composites are lightweight and display exceptional mechanical properties at both ambient and elevated temperatures. These structures achieve a compressive strength that is 10 times higher than the yield strength of the corresponding peak-aged Al alloy at ambient temperature and 14 times higher at 400 °C. Possible strengthening mechanisms are described, and further strategies for improving properties of those composites are proposed.

Numerous metals and metal compounds are often added to propellants and explosives to tailor their properties such as heat release rate and specific impulse. When these materials combust, these metals can be released into the air, causing adverse health effects such as pulmonary and cardiovascular disease, particulate-matter-induced allergies, and cancer. Hence, robust, field-deployable methods are needed to detect and quantify these suspended metallic particles in air, identify their sources, and develop mitigation strategies. Laser-induced breakdown spectroscopy (LIBS) is a technique for elemental detection, commonly used on solids and liquids. In this study, we explored nanosecond-duration LIBS for detecting airborne metals during reactions of solid propellant strands, resulting from additives of aluminum (Al), copper, lead, lead stearate, and mercury chloride. Using the second harmonic of a 10-ns-duration 10-Hz, Nd:YAG laser, plasma was generated in the gas-phase exhaust plume of burning propellant strands containing the target metals. Under the current experimental conditions, the ns-LIBS scheme was capable of detecting Al at concentrations of 5%, 10%, and 16% by weight in the propellant strand. As the weight percentage increased, the LIBS signal was detected by more laser shots, up to a point where the system transition from being nonhomogeneous to a more-uniform distribution of particles. Further measurements and increased understanding of the reacting flow field are necessary to quantify the effects of other metal additives besides Al.

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