Simple, inexpensive synthesis

of damage-tolerant MAX phase

foams
By Liangfa Hu, Ibrahim Karaman, and
Miladin Radovic
-ORETHAN
ternary carbides
and nitrides belong
to the family of
ceramics known as
the MAX phases,
where M is an early
transition metal,
Hu
A is an A-group Figure 1. (a) Variation of normalized compressive strength of Ti2AlC with overall poros-
element, and X ity. Also included are the corresponding data for Al2O3 [16] and Si3N4 [17]. Inset
stands for carbon shows a postcompression, porous Ti2AlC sample that has a volume fraction porosity
and/or nitrogen.1–3 of 0.33. (b) Field emission scanning electron microscopy images reveal the fracture
The growing inter- surface of a postcompression, porous Ti2AlC sample. Inset shows kinking and delami-
nation of Ti2AlC.
est in the MAX
phases over the past mechanical and functional properties.2 samples with a large range of poros-
15 years is driven Second, using porous MAX phases as ITYFROMABOUTTOABOUTVOLAS
by their unusual, melt infiltration preforms creates an well as a wide range of pore sizes, for
Karaman
sometimes unique, alternative for fabricating novel cermet EXAMPLEn—Mn—MAND
combination of SYSTEMS%XAMPLEAPPLICATIONSINCLUDE n—M3
properties typical magnesium melt infiltration into porous NaCl is inexpensive and commer-
of ceramics and MAX phase preforms to make a new cially available in a broad range of
metals. Similar to class of high-strength MAX phase/mag- PARTICLESIZES/RGANICPOREFORMERSCAN
their correspond- nesium composites with exceptional react with MAX phase powders during
ing binary carbide mechanical damping characteristics.4 sintering and form binary carbides if
and nitride ceram- Another application of porous MAX they are not burned out completely at
ics, they have high phases is for catalytic coatings in gas lower temperatures. However, NaCl
Radovic
elastic moduli, high exhaust devices.5 can be removed easily and completely
thermal and electrical conductivities, Porous MAX phases are prepared by after cold-pressing but before sintering,
high chemical resistances, and low either incomplete densification during and it eliminates the potential for reac-
thermal expansion coefficients. sintering of powders4 or by a replica tion between pore former and MAX
/NTHEOTHERHANDTHEYALSOPOSSESS
metal-like properties. For example, they
are relatively soft, and most are readily
machinable, thermal shock resistant,
and damage tolerant. Moreover, they
can be compressed to stresses as high as
'0AANDFULLYRECOVERTHEIRORIGINAL
shapes on removal of the stress, while
method using a polyurethane sponge phase.
template.5 Although it is simple and %XPERIMENTALINVESTIGATIONSSHOW
straightforward, incomplete densifica- that porous MAX phases tolerate dam-
tion does not allow good control over age well. Specifically, the compressive
morphology, porosity, and pore size. strength of Ti2AlC decreases almost
The replica method, on the other hand, linearly with increasing porosity (Figure
allows good control of the pore size and 1(a)), but less rapidly when compared
morphology, but it is complex, time with common ceramics, including
dissipating 25 percent of the mechani-
cal energy.2,3 They also have better
creep resistance than most high-tem-
perature metallic alloys.2,3
Although research on the MAX
phases in the compact, fully dense state
consuming, and not desired for fabricat- Al2/3, Si3N4AND:R/2,8 whose com-
ing samples with low porosity. pressive strengths decrease dramatically
More recently, investigators adapted with increasing porosity.
the use of a NaCl pore former by This strength/porosity relation is
Polonsky et al.6DURINGTHESTO caused partially by the kinking and
fabricate aluminum foams as a simple delamination mechanism that is typi-
HASEXPLODEDSINCETHESVERYFEW
studies have focused on these materials
in the porous state. Porous MAX phases
deserve systematic study for a variety
of reasons. First, controlling porosity
and pore size allows tailoring of their
and inexpensive way of synthesizing cal of deformation in Ti2AlC and, to a
porous Ti2AlC. This three-step method further extent, in all MAX phases. The
involves cold pressing a NaCl–Ti2AlC 3%-IMAGESOFTHEFRACTURESURFACESIN
powder mixture, dissolving the NaCl in Figure 1b reveal intensive kinking and
water, and pressureless sintering of the delamination of porous Ti2AlC that
porous green body. The process yielded dissipate a large amount of mechanical

American Ceramic Society Bulletin, Vol. 92, No. 5 | www.ceramics.org 31

Annual student section
energy during crack propagation. Also,
the relatively low standard deviations
FROMTOPERCENT FORCOMPRES-
sive strengths provide additional evi-
dence of the exceptional damage toler-
ance of Ti2AlC. Because of the wide
range of porosity and pore size, even
more interesting mechanical responses
may be possible.
References
1
M.W. Barsoum, ‘‘The M(N+1)AX(N) phases: A
new class of solids: Thermodynamically stable
nanolaminates,” Prog. Solid State Chem., 28, 201
(2000).
2
Extreme interdisciplinary study
abroad—From sea slugs to gas
turbines
By Brad Richards
Travel abroad for coursework is
a dream of almost all undergraduate
students. At Worcester Polytechnic
Institute (WPI), that dream is realized
by almost half of the student body. For
me, that meant nine weeks in Puerto
Rico in the spring of 2010. However,
this was not a trip to study island culture
or become fluent in the Spanish lan-
guage. Rather, I worked as a field ecolo-
stream when it was 104°C outside and
100 percent humidity, while lugging
a massive backpack. Not typical aero-
space or materials science work! Still, I
cannot deny that it was one of the most
enjoyable experiences in my whole edu-
cation. I can, however, assure you that
it also was one of the most valuable. I
gained something intangible that just
cannot be picked up in a classroom.
When I went to Puerto Rico, I had
already committed to the PhD pro-
gram in materials science at Intelligent
Processing of Materials Lab at the
University of Virginia. This trip did
-7"ARSOUMAND-2ADOVIC@@%LASTICAND
MECHANICALPROPERTIESOFTHE-!8PHASEvP
in Annual Review of Materials Research, Vol. 41.
%DITEDBY$2#LARKEAND0&RATZL am trained in biology and am an avid
3
M. Radovic and M.W. Barsoum, ‘‘MAX phases:
Bridging the gap between metals and ceramics,”
Am. Ceram. Soc. Bull., 92, 20 (2013).
4
S. Amini, C.Y. Ni, and M.W. Barsoum,
‘‘Processing, microstructural characterization, and
mechanical properties of a Ti2AlC/nanocrystal-
line Mg-matrix composite,” Compos. Sci. Technol.,
gist sampling macroinvertebrate popula- not change my desire to work on gas
tions. At this point you may suspect I turbines or to pursue my PhD. It did,
however, change my outlook on my
outdoorsman. I am quite the opposite. work. I started thinking about to whom
The primary purpose of the trip was my work was important, what other
to experience a side of science and engi- disciplines should or could be involved
neering that one would not normally in my research, and how to communi-
encounter in their career path. The goal cate the value of the work to someone
was to learn management skills, how to who does not have a PhD in materials
69 
5
S. Ziqi, L. Ying, L. Meishuan, and Z. Yanchun,
“Preparation of reticulated MAX-phase support
with morphology-controllable nanostructured
ceria coating for gas exhaust catalyst devices,” J.
interact with others, and how to work science. And, at the risk of sounding cli-
outside of my comfort zone. My four- ché, reducing the environmental impact
person team included a chemical engi- of gas turbines is now one of my primary
neer, a biologist, a biomedical engineer, interests in my research.
Am. Ceram. Soc., 93 
6
L. Polonsky and H. Markus, Modern Casting, 39
 

L.F. Hu, R. Benitez, S. Basu, I. Karaman, and
M. Radovic, “Processing and characterization of
porous Ti2AlC with controlled porosity and pore
size,” Acta Mater., 60, 6266 (2012).
8
and an aerospace engineer (yours truly).
Indeed, our project was outside every-
one’s comfort zone.
The project changed how I look at
my discipline and how I look at oth-
ers’ as well. I gained perspective on my
work generally reserved only for one
Most importantly, I learned that we
all are capable of far more diverse exer-
cises than we believe. So, when you get
the chance, do not pass up the oppor-
tunity to step far outside the box. You
may find you are far more capable than
you think. Q
,&(UAND#!7ANGh%FFECTOFSINTERING outside of my field. After all, for this
temperature on compressive strength of porous Brad Richards is a PhD candidate at the
yttria-stabilized zirconia ceramics,” Ceram. Int.,
project, I was very much an outsider in University of Virginia.
36 Q terms of discipline and culture. I felt
similarly an outsider
About the authors (at least briefly) on my
Liangfa Hu is a third-year PhD stu- transition to materi-
dent at Texas A&M University, College als science. The feel-
Station, Texas, in materials science and ing is mellowing, but
engineering, president of the Material the island experience
Advantage chapter at Texas A&M, and taught me to think
PCSA Communications Committee chair. about my work with a
Ibrahim Karaman is a professor in mindset far different
mechanical engineering and materials sci- from the typical engi-
ence and engineering, and the chair of neer or scientist.
(Credit: Brad Richards.)

materials science and engineering inter- I learned to share the

disciplinary graduate program at Texas
A&M University.
Miladin Radovic is an associate profes-
sor in mechanical engineering and materi-
als science and engineering at Texas A&M
University.
passion of others and to
support my team in all
endeavors of our proj- Brad Richards (left) and Michael Ford, also a WPI student,
ect. This occasionally inspect a sea slug during an undergraduate research experi-
meant wearing water- ence in Puerto Rico. Richards is now a graduate student at
proof high-waders in a UVA, where he studies gas turbines.

32 www.ceramics.org | American Ceramic Society Bulletin, Vol. 92, No. 5