A novel route for synthesis of alumina–chromium carbide composites from PTFE-activated Cr2O3/Al/C combustion

Fabrication of alumina-chromium carbide composites was investigated by PTFE-activated Cr₂O₃/Al/C combustion synthesis. PTFE was employed as not only a reaction promoter, but a carburizing agent. Three reaction systems were prepared with different contents of carbon for the synthesis of Cr₂₃C₆, Cr₇C₃, and Cr₃C₂. The amounts of PTFE were selected to ensure combustion synthesis in the SHS (self-propagating high-temperature synthesis) mode and to provide carbon in quantities of 15 and 25?mol% of the total carbon. Experimental results showed that the combustion wave velocity and temperature decreased with increasing carbon, but increased with PTFE. A correlation between combustion wave velocity and temperature contributed to determination of the activation energy E_a =?89.15?kJ/mol for the combustion reaction. The increase of PTFE also improved formation of chromium carbides. As a result, the Cr₂₃C₆– and Cr₇C₃–Al₂O₃ composites were produced with almost no impurities. Due to a loss of carbon in carbothermic reduction, the Cr₃C₂–Al₂O₃ composite was obtained with Cr₇C₃ as the secondary carbide. SEM micrographs and DES analyses indicated that spherical carbide grains with a size of 0.5–3.0 μm were synthesized.