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A new REactive spray FORming (REFORM) process is being developed for the production of titanium aluminides. The REFORM process is potentially capable of synthesizing and forming these materials in a single unit operation. Aluminum powders and TiCl4 vapour have been fed into the tail flame of a d.c. plasma torch which operated on either argon or argon/hydrogen plasmas. The resulting high temperature reaction produced TiAl and Ti3Al intermetallics which were either collected on a cold substrate in a standard plasma spraying operation or quenched and collected as powder. Results of early experiments have produced materials containing up to 40% Ti consistent with the compositions predicted by a thermodynamic analysis. A second set of experiments in which the TiCl4 is introduced to the reaction zone as the plasmagas, resulting in much higher reaction temperatures, is now under way. Microstructures, an energy balance and a thermodynamic analysis are used to assess the extent to which the reaction goes to completion.
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