Formation of Mo₅Si₃/Mo₃Si-MgAl₂O₄ Composites via Self-Propagating High-Temperature Synthesis

In situ formation of intermetallic/ceramic composites composed of molybdenum silicides (Mo₅Si₃ and Mo₃Si) and magnesium aluminate spinel (MgAl₂O₄) was conducted by combustion synthesis with reducing stages in the mode of self-propagating high-temperature synthesis (SHS). The SHS process combined intermetallic combustion between Mo and Si with metallothermic reduction of MoO₃ by Al in the presence of MgO. Experimental evidence showed that combustion velocity and temperature decreased with increasing molar content of Mo₅Si₃ and Mo₃Si, and therefore, the flammability limit determined for the reaction at Mo₅Si₃ or Mo₃Si/MgAl₂O₄ = 2.0. Based upon combustion wave kinetics, the activation energies, E_a = 68.8 and 63.8 kJ/mol, were deduced for the solid-state SHS reactions producing Mo₅Si₃- and Mo₃Si-MgAl₂O₄ composites, respectively. Phase conversion was almost complete after combustion, with the exception of trivial unreacted Mo existing in both composites and a minor amount of Mo₃Si in the Mo₅Si₃-MgAl₂O₄ composite. Both composites display a dense morphology formed by connecting MgAl₂O₄ crystals, within which micro-sized molybdenum silicide grains were embedded. For equimolar Mo₅Si₃- and Mo₃Si-MgAl₂O₄ composites, the hardness and fracture toughness are 14.6 GPa and 6.28 MPa m^1/2, and 13.9 GPa and 5.98 MPa m^1/2, respectively.