Abstract:
A two-phase titanic aluminide alloy having a lamellar microstructure with little intercolony structures. The alloy can include fine particles such as boride particles at colony boundaries and/or grain boundary equiaxed structures. The alloy can include alloying additions such as ≦10 at % W, Nb and/or Mo. The alloy can be free of Cr, V, Mn, Cu and/or Ni and can include, in atomic %, 45 to 55% Ti, 40 to 50% Al, 1 to 5% Nb, 0.3 to 2% W, up to 1% Mo and 0.1 to 0.3% B. In weight %, the alloy can include 57 to 60% Ti, 30 to 32% Al, 4 to 9% Nb, up to 2% Mo, 2 to 8% W and 0.02 to 0.08% B.

Description:
STATEMENT OF GOVERNMENT RIGHTS 
     The United States government has rights in this invention pursuant to contract No. DE-AC05-840R21400 between the United States Department of Energy and Lockheed Martin Energy Research Corporation, Inc. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to two-phase titanium aluminide alloy compositions useful for resistive heating and other applications such as structural applications. 
     BACKGROUND OF THE INVENTION 
     Titanium aluminide alloys are the subject of numerous patents and publications including U.S. Pat. Nos. 4,842,819; 4,917,858; 5,232,661; 5,348,702; 5,350,466; 5,370,839; 5,429,796; 5,503,794; 5,634,992; and 5,746,846, Japanese Patent Publication Nos. 63-171862; 1-259139; and 142539; European Patent Publication No. 365174 and articles by V. R. Ryabov et al entitled “Properties of the Intermetallic Compounds of the System Iron-Alminum” published in Metal Metalloved, 27, No.4, 668673, 1969; S. M. Barinov et al entitled “Deformation and Failure in Titanium Aluminide” published in Izvestiya Akademii Nauk SSSR Metally, No. 3, 164-168, 1984; W. Wunderlich et al entitled “Enhanced Plasticity by Deformation Twinning of Ti-Al-Base Alloys with Cr and S” published in Z. Metallkunde, 802-808, 11/1990; T. Tsujimoto entitled “Research, Development, and Prospects of TiAl Intermetallic Compound Alloys” published in Titanium and Zirconium, Vol. 33, No. 3, 19 pages, 7/1985; N. Maeda entitled “High Temperature Plasticity of Intermetallic Compound TiAl” presented at Material of 53 rd  Meeting of Superplasticity, 13 pages, 1/30/1990; N. Maeda et al entitled “Improvement in Ductility of Intermetallic Compound through Grain Super-refinement” presented at Autumn Symposium of the Japan Institute of Metals, 14 pages, 1989; S. Noda et al entiitled “Mechanical Properties of TiAl Intermetallic Compound” presented at Autumn Symposium of the Japan Institute of Metals, 3 pages, 1988; H. A. Lipsitt entitled “Titanium Aluminides—An Overview” published in Mat. Res. Soc. Symp. Proc. Vol. 39, 351-364, 1985; P. L. Martin et al entitled “The Effects of Alloying on the Microstructure and Properties of Ti 3  Al and TiAl” published by ASM in Titanium 80, Vol. 2, 1245-1254, 1980; S. H. Whang et al entitled “Effect of Rapid Solidification in L 1   0  TiAl Compound Alloys” ASM Symposium Proceedings on Enhanced Properties in Structural Metals Via Rapid Solidification, Materials Week, 7 pages, 1986; and D. Vujic et al entitled “Effect of Rapid Solidification and Alloying Addition on Lattice Distortion and Atomic Ordering in L 1   0  TiAl Alloys and Their Ternary Alloys” published in Metallurgical Transactions A, Vol. 19A, 2445-2455, 10/1988. 
     Methods by which TiAl aluminides can be processed to achieve desirable properties are disclosed in numerous patents and publications such as those mentioned above. In addition, U.S. Pat. No. 5,489,411 discloses a powder metallurgical technique for preparing titanium aluminide foil by plasma spraying a coilable strip, heat treating the strip to relieve residual stresses, placing the rough sides of two such strips together and squeezing the strips together between pressure bonding rolls, followed by solution annealing, cold rolling and intermediate anneals. U.S. Pat. No. 4,917,858 discloses a powder metallurgical technique for making titanium aluminide foil using elemental titanium, aluminum and other alloying elements. U.S. Pat. No. 5,634,992 discloses a method of processing a gamma titanium aluminide by consolidating a casting and heat treating the consolidated casting above the eutectoid to form gamma grains plus lamellar colonies of alpha and gamma phase, heat treating below the eutectoid to grow gamma grains within the colony structure and heat treating below the alpha tansus to reform any remaining colony structure a structure having % laths within gamma grains. 
     Still, in view of the extensive efforts to improve properties of titanium aluminides, there is a need for improved alloy compositions and economical processing routes. 
     According to a first embodiment, the invention provides a two-phase titanium aluminum alloy having a lamellar microstructure controlled by colony size. The alloy can be provided in various forms such as in the as-cast, hot extruded, cold and hot worked, or heat treated condition. As an end product, the alloy can be fabricated into an electrical resistance heating element having a resistivity of 60 to 200 μΩ-cm. The alloy can include additional elements which provide fine particles such as second-phase or boride particles at colony boundaries. The alloy can include grain-boundary equiaxed structures. The additional alloying elements can include, for example, up to 10 at % W, Nb and/or Mo. The alloy can be processed into a thin sheet having a yield strength of more than 80 ksi (560 MPa), an ultimate tensile strength of more than 90 ksi (630 MPa), and/or tensile elongation of at least 1.5%. The aluminum can be present in an amount of 40 to 50 at %, preferably about 46 at %. The titanium can be present in the amount of at least 45 at %, preferably at least 50 at %. As an example, the alloy can include 45 to 55 at % Ti, 40 to 50 at % Al, 1 to 5 at % Nb, 0.5 to 2 at % W, and 0.1 to 0.3 at % B. The alloy is preferably free of Cr, V, Mn and/or Ni. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 a-d  are optical micrographs at 200× of PMTA TiAl alloys hot extruded at 1400° C. and annealed for 2 hours at 1000° C. FIG. 1 a  shows the microstructure of PMTA-1, FIG. 1 b  shows the microstructure of PMTA-2, FIG. 1 c  shows the microstructure of PMTA-3 and FIG. 1 d  shows the microstructure of PMTA4; 
     FIGS. 2 a-d  show optical micrographs at 500× of PMTA alloys hot extruded at 1400° C. and annealed for 2 hours at 1000° C. FIG. 2 a  shows the microstructure of PMTA-1, FIG. 2 b  shows the microstructure of PMAT-2, FIG. 2 c  shows the microstructure of PMAT-3 and FIG. 2 d  shows the microstructure of PMTA4; 
     FIG. 3 shows ghost-pattern bands observed in a back-scattered image of PMTA-2 hot extruded at 1400° C. and annealed for 2 hours at 1000° C. wherein the non-uniform distribution of W is shown; 
     FIG. 4 shows a back-scattered image of PMTA-2 hot extruded at 1400° C. and annealed for 2 hours at 1000° C.; 
     FIG. 5 a  is a micrograph at 200× of PMTA-3 hot extruded at 1400° C and annealed for one day at 1000° C. and FIG. 5 b  shows the same microstructure at 500 ×; 
     FIG. 6 a  shows the microstructure at 200× of PMTA-2 hot extruded at 1400° C. and annealed for 3 days at 1000° C. and FIG. 6 b  shows the same microstructure at 500 ×; 
     FIG. 7 a  is an optical micrograph of TiAl sheet (Ti45Al-5Cr, at %) in the as-received condition and FIG. 7 b  shows the same microstructure after annealing for 3 days at 1000° C., both micrographs at 500 ×; 
     FIG. 8 a  shows a micrograph of PMTA-6 and FIG. 8 b  shows a micrograph of PMTA-7, both of which were hot extruded at 1380° C. (magnification 200 ×); 
     FIG. 9 a  is a micrograph of PMTAL and FIG. 9 b  is a micrograph of PMTA-7, both of which were hot extruded at 1365° C. (magnification 200 ×); 
     FIG. 10 is micrograph showing abnormal grain growth in PMTA hot extruded at 1380° C.; 
     FIGS. 11 a-d  are micrographs of PMTA-8 heat treated at different conditions after hot extrusion at 1335° C., the heat treatments being two hours at 1000° C. for FIG. 11 a,  30 minutes at 1340° C. for FIG. 11 b,  30 minutes at 1320° C. for FIG. 11 c,  and 30 minutes at 1315° C. for FIG. 11 d  (magnification  200 ×);    
     FIG. 12 is a graph of resistivity in microhms versus temperature for samples 1 and 2 cut from an ingot having a PMTA4 nominal composition; 
     FIG. 13 is a graph of hemispherical total emissivity versus temperature for samples 1 and 2; 
     FIG. 14 is a graph of diffusivity versus temperature for samples 80259-1, 80259-2 and 80259-3 cut from the same ingot as samples 1 and 2; 
     FIG. 15 is a graph of specific heat versus temperature for titanium aluminide in accordance with the invention; and 
     FIG. 16 is a graph of thermal expansion versus temperature for samples 80259-1H, 80259-1C, 80259-2H, 80259-3H, and 80259-3C cut from the same ingot as samples 1 and 2. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention provides two-phase TiAl alloys with thermo-physical and mechanical properties useful for various applications such as resistance heater elements. The alloys exhibit useful mechanical properties and corrosion resistance at elevated temperatures up to 1000° C. and above. The TiAl alloys have extremely low material density (about 4.0 g/cm 3 ), a desirable combination of tensile ductility and strength at room and elevated temperatures, high electrical resistance, and/or can be fabricated into sheet material with thickness &lt;10 mil. One use of such sheet material is for resistive heating elements of devices such as cigarette lighters. For instance, the sheet can be formed into a tubular heating element having a series of heating strips which are individually powered for lighting portions of a cigarette in an electrical smoking device of the type disclosed in U.S. Pat. Nos. 5,591,368 and 5,530,225, the disclosures of which are hereby incorporated by reference. In addition, the alloys can be free of elements such as Cr, V, Mn and/or Ni. 
     Compared to TiAl alloys containing 1 to 4 at % Cr, V, and/or Mn for improving tensile ductility at ambient temperatures, according to the present invention, tensile ductility of dual-phase TiAI alloys with lamellar structures can be mainly controlled by colony size, rather than such alloying elements. The invention thus provides high strength TiAl alloys which can be free of Cr, V, Mn and/or Ni. 
     Table 1 lists nominal compositions of alloys investigated wherein the base alloy contains 46.5 at % Al, balance Ti. Small amounts of alloying additions were added for investigating effects on mechanical and metallurgical properties of the twophase TiAl alloys. Nb in amounts up to 4% was examined for possible effects on oxidation resistance, W in amounts of up to 1.0% was examined for effects on microstructural stability and creep resistance, and Mo in amounts of up to 0.5% was examined for effects on hot fabrication. Boron in amounts up to 0.18% was added for refinement of lamellar structures in the dual-phase TiAl alloys. 
     Eight alloys identified as PMTA-1 to 9, having the compositions listed in Table 1, were prepared by arc melting and drop casting into a 1″ diameter×5″ long copper mold, using commercially-pure metals. All the alloys were successfully cast without casting defects. Seven alloy ingots (PMTA -1 to 4 and 6 to 9) were then canned in Mo cans and hot extruded at 1335 to 1400° C. with an extrusion ratio of 5:1 to 6:1. The extrusion conditions are listed in Table 2. The cooling rate after extrusion was controlled by air cooling and quenching the extruded rods in water for a short time. The alloy rods extruded at 1365 to 1400° C. showed an irregular shape whereas PMTA-8 hotextruded at 1335° C. exhibited much smoother surfaces without surface irregularities. However, no cracks were observed in any of the hot-extruded alloy rods. 
     The microstructures of the alloys were examined in the as-cast and heat treated conditions (listed in Table 2) by optical metallography and electron superprobe analyses. In the as-cast condition, all the alloys showed lamellar structure with some degree of segregation and coring. FIGS. 1 and 2 show the optical micrographs, with a magnification of 200 × and 500 ×, respectively, for hot extruded alloys PMTA-1 to 4 stress-relieved for 2 hours at 1000° C. All the alloys showed fully lamellar structures, with a small amount of equiaxed grain structures at colony boundaries. Some fine particles were observed at colony boundaries, which are identified as borides by electron microprobe analyses. Also, there is no apparent difference in microstructural features among these four PMTA alloys. 
     Electron microprobe analyses reveal that tungsten is not uniformly distributed even in the hot extruded alloys. As shown in FIG. 3, the ghost-pattern bands in a darker contrast are found to be depleted with about 0.33 at % W. FIG. 4 is a back-scattered image of PMTA-2, showing the formation of second-phase particles (borides) in a bright contrast at colony boundaries. The composition of the borides was determined and listed in Table 3 together with that of the lamellar matrix. The second-phase particles are essentially (Ti,W,Nb) borides, which are decorated and pinned lamellar colony boundaries. 
     FIGS. 5 and 6 show the optical microstructures of hot extruded PMTA-3 and 2 annealed for 1 day and 3 days at 1000° C., respectively. Grain-boundary equiaxed structures are clearly observed in these long-term annealed specimens, and the amount increases with the annealing time at 1000° C. A significant amount of equiaxed grain structures exists in the specimen annealed for 3 days at 1000° C. 
     For comparison purposes, a 9-mil thick TiAl sheet (Ti45Al-5Cr, at %) was evaluated. FIG. 7 shows the optical microstructures of the TiAlCr sheet in both as-received and annealed (3 days at 1000° C.) conditions. In contrast to the dual-phase lamellar structure of the alloys according to the invention, the TiAlCr sheet has a duplex structure, and its grain structure shows no significant coarsening at 1000° C. 
     Tensile sheet specimens with a thickness of 9-20 mils and a gage length of 0.5 in were sectioned from the hot extruded alloys rods after annealing for 2 hours at 1000° C., using a EDM machine. Some of the specimens were re-annealed up to 3 days at 1000° C. prior to tensile testing. Tensile tests were performed on an Instron testing machine at a strain rate of 0.1 inch/second at room temperature. Table 4 summarizes the tensile test results. 
     All the alloys stress-relieved for 2 hours at 1000° C. exhibited 1% or more tensile elongation at room temperature in air. The tensile elongation was not affected when the specimen thickness varied from 9 to 20 mils. As indicated in Table 4, among the 4 alloys, alloy PMTAA appears to have the best tensile ductility. It should be noted that a tensile elongation of 1.6% obtained from a 20-mil thick sheet specimen is equivalent to 4% elongation obtained from rod specimens with a gage diameter of 0.12 in. The tensile elongation appears to increase somewhat with annealing time at 1000° C., and the maximum ductility is obtained in the specimen annealed for 1 day at 1000° C. 
     All the alloys are exceptionally strong, with a yield strength of more than 100 ksi (700 MPa) and ultimate tensile strength more than 115 ksi (800 MPa) at room temperature. The high strength is due to the refined fully lamellar structures produced in these TiAl alloys. In comparison, the TiAlCr sheet material has a yield strength of only 61 ksi (420 MPa) at room temperature. Thus, the PMTA alloys are stronger that the TiAlCr sheet by as much as 67%. The PMTA alloys including 0.5% Mo exhibited significantly increased strengths, but slightly lower tensile elongation at room temperature. 
     FIGS. 8 a-b  and  9   a-b  show the optical micrographs of PMTA6 and 7 hot extruded at 1380° C. and 1365° C., respectively. Both alloys showed lamellar grain structures with little intercolony structures. Large colony grains (see FIG. 10) were observed in both alloys hot extruded at 1380° C. and 1365° C., which probably resulted from abnormal grain growth in the alloys containing low levels of boron after hot extrusion. There is no significant difference in microstructural features in these two PMTA alloys. 
     FIGS. 11 a-d  show the effect of heat treatment on microstructures of PMTA-8 hot extruded at 1335° C. The alloy extruded at 1335° C. showed much fewer colony size and much more intercolony structures, as compared with those hot extruded at 1380° C. and 1365° C. Heat treatment for 2 h at 1000° C. did not produce any significant change in the as-extruded structure (FIG. 11 a ). However, heat treatment for 30 mins at 1340° C. resulted in a substantially larger colony structure (FIG. 11 b ). Lowering the heat-treatment temperature from 1340° C. to 1320-1315° C. (a difference by 20-25° C.) produced a sharp decrease in colony size, as indicated by FIGS. 11 c  and  11   d.  The annealing at 1320-1315° C. also appears to produce more intercolony structures in PMTA-8. The abnormal grain growth is almost completely eliminated by hot extrusion at 1335° C. 
     Tensile sheet specimens of PMTA-6 to 8 with a thickness varying from 8 to 22 mils and with a gage length of 0.5 inch were sectioned from the hot extruded alloy rods after giving a final heat treatment of 2 h at 1000° C. or 20 min at 1320-1315° C., using an EDM machine. Tensile tests were performed on an Instron testing machine at a strain rate of 0.1 in/s at temperatures up to 800° C. in air. All tensile results are listed in Tables 5 to 8. The alloys PMTA4, -6 and -7 heat treated for 2 h at 1000° C. showed excellent strengths at all temperatures, independent of hot extrusion temperature. The hot extrusion at 1400-1365° C. gives low tensile ductilities (&lt;4%) at room and elevated temperatures. A significant increase in tensile ductility is obtained at all temperatures when hot extruded at 1335° C. PMTA-8 which was hot extruded at 1335° C. exhibited the highest strength and tensile ductility at all test temperatures. There did not appear to be any systematical variation of tensile ductility with specimen thickness varying from 8 to 22 mils. 
     Tables 7 and 8 also show the tensile properties of PMTA- 6 and 7 heat treated for 20 min. at 1320° C. and 1315° C., respectively. As compared with the results obtained from heat treatment at 1000° C., the heat treatment at 1320-1315° C. resulted in higher tensile elongation, but lower strength at the test temperatures. Among all the alloys and heat treatments, PMTA-8 hot extruded at 1335° C. and annealed for 20 min at 1315° C. exhibited the best tensile ductility at room and elevated temperatures. This alloy showed a tensile ductility of 3.3% and 11.7% at room temperature and 800° C., respectively. PMTA-8 heat treated at 1315° C. appears to be substantially stronger than known TiAl alloys. 
     In an attempt to demonstrate the bend ductility of TiAl sheet material, several pieces of 11 to 20 mil PMTA-7 and PMTA-8 alloy sheets, produced by hot extrusion and heat treated at 1320° C., were bent at room temperature. Each alloy piece did not fracture after a bend of 42°. These results clearly indicate that PMTA alloys with a controlled microstructure is bendable at room temperature. 
     The oxidation behavior of PMTA-2, -5 and-7 was studied by exposing sheet samples (9-20 mils thick) at 800° C. in air. The samples were periodically removed from furnaces for weight measurement and surface examination. The samples showed a very low weight gain without any indication of spalling. It appears that the alloying additions of W and Nb affect the oxidation rate of the alloys at 800° C., and W is more effective in improving the oxidation resistance of TiAl alloys. Among the alloys, PMTA-7 exhibits the lowest weight gain and the best oxidation resistance at 800° C. Oxidation of PMTA-7 indicated that oxide scales are fully adherent with no indication of microcracking and spaling. This observation clearly suggests that the oxide scales formed at 800° C. are well adherent to the base material and are very protective. 
     FIG. 12 is a graph of resistivity in microhms versus temperature for samples 1 and 2 which were cut from an ingot having a nominal composition of PMTA4, i.e. 30.8 wt % Al, 7.1 wt % Nb, 2.4 wt % W, and 0.045 wt % B.; FIG. 13 is a graph of hemispherical total emissivity versus temperature for samples 1 and 2; FIG. 14 is a graph of diffusivity versus temperature for samples 80259-1, 80259-2 and 80259-3 cut from the same ingot as samples 1 and 2; FIG. 15 is a graph of specific heat versus temperature for titanium aluminide in accordance with the invention; and FIG. 16 is a graph of thermal expansion versus temperature for samples 80259-1H, 80259-1C, 80259-2H, 80259-3H, and 80259-3C cut from the same ingot as samples 1 and 2. 
     In summary, the hot PMTA alloys extruded at 1365 to 1400° C. exhibited mainly lamellar structures with little intercolony structures while PMTA-8 extruded at 1335° C. showed much finer colony structures and more intercolony structures. The heat treatment of PMTA-8 at 1315-1320° C. for 20 min. resulted in fine lamellar structures. The alloys may include (Ti,W,Nb) borides formed at colony boundaries. Moreover, tungsten in the hot-extruded alloys is not uniformly distributed, suggesting the possibility of high electrical resistance of TiAI alloys containing W additions. The inclusion of 0.5 at. % Mo significantly increases the yield and ultimate tensile strengths of the TiAl alloys, but lowers the tensile elongation to a certain extent at room temperature. Among the four hot extruded alloys PMTA 14, PMTA4 with the alloy composition Ti-46.5 Al-3 Nb-0.5 W-0.2 B (at %) has the best combination of tensile ductility and strength at room temperature. In comparison with the TiAICr sheet material (Ti45 Al-5Cr), PMTA4 is stronger than the TiAICr sheet by 67%. In addition, the TiAlCr sheet showed no bend ductility at room temperature while PMTAA has an elongation of 1.4%. The tensile elongation of TiAl alloys is independent of sheet thickness in the range of 9 to 20 mils. The alloys PMTA 4, 6 and 7 heat treated at 1000° C. for 2 h showed excellent strength at all temperatures up to 800° C., independent of hot extrusion temperature. Hot extrusion temperatures of 1400-1365° C., however, provides lower tensile ductilities (&lt;4%) at room and elevated temperatures. A significant increase in tensile ductility is obtained at all temperatures when the extrusion temperature is 1335° C. PMTA-8 (Ti46.5 Al-3 Nb-1W-0.5B) hot extruded at 1335° C. and annealed at 1315° C. for 20 min. exhibited the best tensile ductility at room and elevated temperatures (3.3% at room temperature and 11.7% at 800° C.). 
     
       
         
               
             
               
               
               
               
               
               
               
               
             
               
               
             
               
               
               
               
               
               
               
               
             
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Nominal Alloy Compositions 
               
             
          
           
               
                 Alloy 
                   
                   
                   
                   
                   
                   
                   
               
               
                 number 
                 Ti 
                 A1 
                 Cr 
                 Nb 
                 Mo 
                 W 
                 B 
               
               
                   
               
             
          
           
               
                   
                 Compositions (at %) 
               
             
          
           
               
                 PMTA-1 
                 50.35 
                 46.5 
                  0 
                    2 
                 0.5 
                 0.5 
                  0.15 
               
               
                 PMTA-2 
                 50.35 
                 46.5 
                 0 
                 2 
                 — 
                 1.0 
                 0.15 
               
               
                 PMTA-3 
                 49.85 
                 46.5 
                 0 
                 2 
                 0.5 
                 1.0 
                 0.15 
               
               
                 PMTA-4 
                 49.85 
                 46.5 
                 0 
                 3 
                 — 
                 0.5 
                 0.15 
               
               
                 PMTA-5 
                 47.85 
                 46.5 
                 0 
                 4 
                 — 
                 0.5 
                 0.15 
               
               
                 PMTA-6 
                 49.92 
                 46.5 
                 0 
                 3 
                 — 
                 0.5 
                 0.08 
               
               
                 PMTA-7 
                 49.92 
                 46.5 
                 0 
                 3 
                 — 
                 1.0 
                 0.08 
               
               
                 PMTA-8 
                 49.40 
                 46.5 
                 0 
                 3 
                 — 
                 1.0 
                 0.10 
               
               
                 PMTA-9 
                 49.32 
                 46.5 
                 0 
                 3 
                 — 
                 1.0 
                 0.18 
               
             
          
           
               
                   
                 Compositions (wt %) 
               
             
          
           
               
                 PMTA-1 
                 60.46 
                 31.36 
                  0 
                  4.64 
                 1.20 
                 2.30 
                  0.04 
               
               
                 PMTA-2 
                 59.80 
                 31.02 
                 0 
                 4.60 
                 — 
                 4.54 
                 0.04 
               
               
                 PMTA-3 
                 58.86 
                 30.83 
                 0 
                 4.57 
                 1.18 
                 4.52 
                 0.04 
               
               
                 PMTA-4 
                 59.55 
                 31.19 
                 0 
                 6.93 
                 — 
                 2.29 
                 0.04 
               
               
                 PMTA-5 
                 57.71 
                 30.85 
                 0 
                 9.14 
                 — 
                 2.26 
                 0.04 
               
               
                 PMTA-6 
                 59.56 
                 31.20 
                 0 
                 6.93 
                 — 
                 2.29 
                 0.02 
               
               
                 PMTA-7 
                 57.98 
                 30.68 
                 0 
                 6.82 
                 — 
                 4.50 
                 0.02 
               
               
                 PMTA-8 
                 57.98 
                 30.68 
                 0 
                 6.82 
                 — 
                 4.50 
                 0.02 
               
               
                 PMTA-9 
                 57.97 
                 30.67 
                 0 
                 6.82 
                 — 
                 4.49 
                 0.05 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Fabrication and Heat Treatment Condition Used for PMTA Alloys 
               
             
          
           
               
                   
                 Hot extrusion 
                   
               
               
                 Alloy number 
                 temperature (° C.) 
                 Heat treatment (° C./time) 
               
               
                   
               
               
                 PMTA-1 
                 1400 
                 1000° C. for up to 3 days 
               
               
                 PMTA-2 
                 1400 
                 1000° C. for up to 3 days 
               
               
                 PMTA-3 
                 1400 
                 1000° C. for up to 3 days 
               
               
                 PMTA-4 
                 1400 
                 1000° C. for up to 3 days 
               
               
                 PMTA-5 
               
               
                 PMTA-6 
                 1380, 1365 
                 1000° C./2 hours 
               
               
                 PMTA-7 
                 1380, 1365 
                 1000° C./2 hr, 1320° C./20 min 
               
               
                 PMTA-8 
                 1335 
                 1000° C./2 hr, 1315° C./20 min 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Phase Compositions in PMTA-2 Alloy Determined 
               
               
                 by Electron Microphobe Analyses 
               
             
          
           
               
                   
                 Alloy elements (at %) 
               
             
          
           
               
                   
                 Phase 
                 Ti 
                 Al 
                 W 
                 Nb 
               
               
                   
                   
               
               
                   
                 Matrix phase 
                 Balance 
                 44.96 
                 0.82 
                 1.32 
               
               
                   
                 (dark contrast) 
               
               
                   
                 Matrix phase 
                 Balance 
                 44.70 
                 1.15 
                 1.32 
               
               
                   
                 (bright contrast) 
               
               
                   
                 Borides* 
                 77.69 
                  8.66 
                 9.98 
                 3.67 
               
               
                   
                   
               
               
                   
                 *metals elements only  
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
           
               
                 TABLE 4 
               
             
             
               
                   
               
               
                 Tensile Properties of PMTA Alloys 
               
               
                 Hot Extruded at 1400° C. and Tested at Room Temperature 
               
             
          
           
               
                   
                 Composition 
                 Tensile 
                   
                   
               
               
                   
                 Nb—Mo—W 
                 elongation 
                 σ y   
                 ρ ue   
               
               
                 Alloy number 
                 (at %) 
                 (%) 
                 (ksi) 
                 (ksi) 
               
               
                   
               
             
          
           
               
                 2 hours/1000° C. 
               
             
          
           
               
                 PMTA-1 
                 2/0.5/0.5 
                 1.0 
                 114 
                 118 
               
               
                 PMTA-2 
                 2/0/1.0 
                 1.2 
                 104 
                 117 
               
               
                 PMTA-3 
                 2/0.5/1.0 
                 1.1 
                 123 
                 132 
               
               
                 PMTA-4 
                 3/0/0.5 
                 1.4 
                 102 
                 115 
               
             
          
           
               
                 1 day/1000° C. 
               
             
          
           
               
                 PMTA-3 
                 2/0.5/1.0 
                 1.4 
                 115 
                 131 
               
             
          
           
               
                 3 days/1000° C. 
               
             
          
           
               
                 PMTA-2 
                 2/0/1.0 
                 0.8 
                 105 
                 109 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 5 
               
             
             
               
                   
               
               
                 Tensile Properties of PMTA-4 Hot Extruded at 
               
               
                 1400° C. and Annealed for 2 h at 1000° C. 
               
             
          
           
               
                 Test temperature 
                 Yield strength 
                 Ultimate tensile 
                 Elongation 
               
               
                 (° C.) 
                 (ksi) 
                 strength (ksi) 
                 (%) 
               
               
                   
               
               
                  22 
                 102.0 
                 115 
                 1.4 
               
               
                 600 
                 101.0 
                 127 
                 2.4 
               
               
                 700 
                  96.5 
                 130 
                 2.7 
               
               
                 800 
                  97.8 
                 118 
                 2.4 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 6 
               
             
             
               
                   
               
               
                 Tensile Properties of PMTA-6 Hot Extruded at 
               
               
                 1365° C. and Annealed at 1000° C. for 2 h 
               
             
          
           
               
                 Test temperature 
                 Yield strength 
                 Ultimate tensile 
                 Elongation 
               
               
                 (° C.) 
                 (ksi) 
                 strength (ksi) 
                 (%) 
               
               
                   
               
               
                  22 
                 121.0 
                 136 
                 1.3 
               
               
                 300 
                 101.0 
                 113 
                 1.2 
               
               
                 700 
                  93.6 
                 125 
                 2.7 
               
               
                 800 
                  86.5 
                 125 
                 3.9 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                 TABLE 7 
               
             
             
               
                   
               
               
                 Tensile Properties of PMTA-7 Hot Extruded at 1365° C. 
               
             
          
           
               
                 Test temperature 
                 Yield strength 
                 Ultimate tensile 
                 Elongation 
               
               
                 (° C.) 
                 (ksi) 
                 strength (ksi) 
                 (%) 
               
               
                   
               
             
          
           
               
                 Annealed for 2 h at 1000° C. 
               
             
          
           
               
                  22 
                 116.0 
                 122 
                 1.0 
               
               
                 300 
                 101.0 
                 116 
                 1.5 
               
               
                 700 
                 105.0 
                 131 
                 2.7 
               
               
                 800 
                  87.2 
                 121 
                 3.1 
               
             
          
           
               
                 Annealed for 20 min at 1320° C. 
               
             
          
           
               
                  20 
                  84.5 
                 106.0 
                 3.0 
               
               
                 300 
                  71.4 
                 89.8 
                 2.5 
               
               
                 700 
                  68.5 
                 97.2 
                 4.5 
               
               
                 800 
                  63.5 
                 90.2 
                 4.5 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                 TABLE 8 
               
             
             
               
                   
               
               
                 Tensile Properties of PMTA-8 Hot Extruder at 1335° C. 
               
             
          
           
               
                 Test temperature 
                 Yield strength 
                 Ultimate tensile 
                 Elongation 
               
               
                 (° C.) 
                 (ksi) 
                 strength (ksi) 
                 (%) 
               
               
                   
               
             
          
           
               
                 Annealed for 2 h at 1000° C. 
               
             
          
           
               
                  22 
                 122.0 
                 140 
                 2.0 
               
               
                 300 
                 102.0 
                 137 
                 4.3 
               
               
                 700 
                 95.0 
                 131 
                 4.7 
               
               
                 800 
                 90.2 
                 124 
                 5.6 
               
             
          
           
               
                 Annealed for 20 min at 1315° C. 
               
             
          
           
               
                  20 
                 96.2 
                 116 
                 3.3 
               
               
                 300 
                 79.4 
                 115 
                 6.1 
               
               
                 700 
                 72.2 
                 112 
                 7.5 
               
               
                 800 
                 72.0 
                 100 
                 11.7 
               
               
                   
               
             
          
         
       
     
     The foregoing titanium aluminide can be manufactured into various shapes or products such as electrical resistance heating elements. However, the compositions disclosed herein can be used for other purposes such as in thermal spray applications wherein the compositions could be used as coatings having oxidation and corrosion resistance. Also, the compositions could be used as oxidation and corrosion resistant electrodes, furnace components, chemical reactors, sulfidization resistant materials, corrosion resistant materials for use in the chemical industry, pipe for conveying coal slurry or coal tar, substrate materials for catalytic converters, exhaust walls and turbocharger rotors for automotive and diesel engines, porous filters, etc. 
     With respect to resistance heating elements, the geometry of the heating element blades can be varied to optimize heater resistance according to the formula: R=ρ(L/W×T) wherein R=resistance of the heater, ρ=resistivity of the heater material, L=length of heater, W=width of heater and T=thickness of heater. The resistivity of the heater material can be varied by changes in composition such as adjusting the aluminum content of the heater material, processing or by incorporation of alloying additions. For instance, the resistivity can be significantly increased by incorporating particles of alumina in the heater material. The heater material can optionally include ceramic particles to enhance creep resistance and/or thermal conductivity. For instance, the heater material can include particles or fibers of electrically conductive material such as nitrides of transition metals (Zr, Ti, Hf), carbides of transition metals, borides of transition metals and MoSs for purposes of providing good high temperature creep resistance up to 1200° C. and also excellent oxidation resistance. The heater material may also incorporate particles of electrically insulating material such as Al 2 O 3 , Y 2 O 3 , Si 3 N 4 , ZrO 2  for purposes of making the heater material creep resistant at high temperature and also improving thermal conductivity and/or reducing the thermal coefficient of expansion of the heater material. The electrically insulating/conductive particles/fibers can be added to a powder mixture of Fe, Al, Ti or iron aluminide or such particles/fibers can be formed by reaction synthesis of elemental powders which react exothermically during manufacture of the heater element. 
     The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. Thus, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.