High-throughput thermodynamic screening of carbide/refractory metal cermets for ultra-high temperature applications

Carbide/refractory metal cermets possess attractive combinations of thermal and mechanical properties for ultra-high temperature structural applications. Using a high-throughput computational thermodynamic approach, 16 carbide/refractory metal cermet systems were identified, out of 1808 possible combinations, that could be fabricated by the displacive compensation of porosity (DCP) method using molten copper alloys as infiltrators at 1300 degrees C. Experimental results for ZrC/W and ZrC/Mo, and other proposed systems in the literature provide a level of validation to this approach. We found that copper alloys are more suitable for DCP than aluminum alloys owing to the low melting temperature of copper alloys (e.g., Zr2Cu and Ti2Cu), and the minimal chemical reaction as well as very limited mutual solid solubility of copper with refractory metals. Our results show that high-throughput thermodynamics calculation is a robust approach for systematically and thoroughly identifying refractory metal cermets that are suitable for DCP.