Processing and characterization of an hybrid fiber reinforced Ni aluminide

A processing route for a high temperature, fiber-reinforced superalloy matrix composite is described. Particular emphasis is placed on achieving low cost while meeting performance objectives. The issue of affordability is addressed by (1) the selection of slurry casting as a means of combining matrix and fiber; (2) the incorporation of a novel oxide fiber based on low cost alumina tows; and (3) the development of microstructural evolution models for the application of intelligent processing concepts. Results of initial metallographic studies of as-cast and as-consolidated samples are presented and used to introduce microstructural features whose evolution during processing must be guided in order to achieve optimal cost and performance. Process-structure modeling approaches currently being explored are briefly described.