Combination of electrophoretic deposition and microwave-ignited combustion synthesis for the preparation of ceramic coated intermetallic-based materials

Electrophoretic deposition (EPD) was used to deposit sub-micrometric ZrO2 particles on metallic powder compacts belonging to the systems Ni + Al and Ti + Al, which were used as deposition electrodes in the EPD cell. After EPD, combustion synthesis (CS) of such reactive electrodes was ignited in a microwave single-mode applicator, operating at a frequency of 2.45 GHz, in order to obtain in a single step the synthesis of the desired intermetallic phase (substrate) and the sintering of the previously deposited ceramic particles (or coating). Experimental results demonstrate that the excess heat released during the formation of nickel and titanium aluminides by CS can be exploited not only to self-sustain and self-propagate the reaction front along the substrate, but also to rapidly sinter the coating obtained by EPD. The innovative procedure here proposed is a promising strategy in order to obtain, in a single step, high temperature intermetallic-based materials, protected by well adhered ceramic coatings.