Reactive laser synthesis of ultra-high-temperature ceramics HfC, ZrC, TiC, HfN, ZrN, and TiN for additive manufacturing

Ultra-high-temperature ceramics (UHTCs) are optimal structural materials for applications that require extreme temperature resilience, resistance to chemically aggressive environments, wear, and mechanical stress. Processing UHTCs with laser-based additive manufacturing (AM) has not been fully realized due to a variety of obstacles. In this work, selective laser reaction sintering (SLRS) techniques were investigated for the production of near net-shape UHTC ceramics such as HfC, ZrC, TiC, HfN, ZrN, and TiN. Group IV transition metal and metal oxide precursor materials were chemically converted and reaction-bonded into layers of UHTCs using single-step selective laser processing in CH4 or NH3 gas that might be compatible with prevailing powder bed fusion techniques. Conversion of either metals (Hf, Zr and Ti) or metal oxides (HfO2, ZrO2, and TiO2) particles was first investigated to examine reaction mechanisms and volume changes associated with SLRS of single-component precursor systems. SLRS processing of metal or metal oxide alone produced near stoichiometric UHTC phases with yields up to 100 wt% total for carbides and nitrides. However, for single component precursors, gas-solid reactivity induced volumetric changes resulted in residual stresses and cracking in the product layer. To mitigate conversion-induced stresses, composite metal/metal oxide precursors were employed to compensate for the volume changes of either the metal (which expands during conversion) or the metal oxide precursor (which contracts).