A Novel Method for Preparing Intermetallics/Superalloy Dissimilar Materials Using Current Sintering of Metallic Powders

Herein, a novel method is proposed to prepare the multimaterial composite component for aerospace applications using the current sintering. Two representative high‐temperature structural materials, the new potential intermetallic NiAl and the widely used Ni‐based superalloy K4202, have been employed to achieve the target. As shown by the results, a clean interface with almost no defects is successfully obtained in NiAl/K4202 alloy. Nevertheless, the existence of a continuous Cr(Mo) phase along the region leads to an insufficient bonding ability. To optimize the interfacial microstructure, a Ni foil is employed as the interlayer. The results indicate that the interlayer can hinder the intense diffusion of elements and prevent the abnormal growth of Cr(Mo) phases, which result in a considerable improvement of interfacial properties. A novel method is proposed to prepare NiAl‐based intermetallics/K4202 superalloy dissimilar materials using the solid‐state sintering‐joining method. A clean interface with no defects is obtained in NiAl/K4202 material. Nevertheless, the existence of a continuous Cr(Mo) phase along the region leads to insufficient bonding. A Ni foil is used as the interlayer, which improves the interfacial strength. The relationship between the property and microstructure of the interface has been revealed.