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The joining of intermetallic parts to the metals (Ti, Al, Cu, Ni) or different intermetallics (e.g. NiAl, TiAl) is important for high-temperature applications. Traditional fusion welding is difficult to apply due to the large thermal expansion mismatch between the intermetallics to be joined and the filler material. Brazing and diffusion bonding are also inefficient, energy-consuming, and must be carried out in vacuum or protective atmosphere. Meanwhile, Self-propagating High-temperature Synthesis (SHS) that is widely used for production of powders, compact materials and parts holds considerable promise as a method of joining various component parts. We report on a new SHS-based approach to joining TiAl and NiAl intermetallics with metal substrates Ti and Ni. The adiabatic combustion temperatures for the systems under study and stoichiometric ratios of green mixtures were determined by thermodynamic calculations. Experiments were performed in the modes of pressure-assisted thermal explosion and combustion wave propagation, with the samples placed between the punches of experimental set up. Investigated were the processes taking place in thermally treated Ti or Ni plates mechanically impregnated (by Mechanically Activation or Vibration Milling) with a mixture of metallic particles. Vibratory treatment of an Al and Ti surfaces in a powder mixture of metals was found to result in destruction of the surface oxide film and formation of extensive physical contacts between the Ni or Ti matrix and the metallic particles mechanically impregnated into the near surface layer of Ni or Ti.Subsequent thermal treatment was then used to launch chemical reaction yielding intermetallides within the impregnated layer. Performing SHS reactions yielding melted intermetallides in the coatings (or pellets) deposited (or placed) onto the surface of thus treated Ti or Ni plates, one can obtain strong weld joining between solidified SHS products and substrates. This approach can also be used for deposition of coatings with a desired composition onto substrates.

For over past years, interest of leading space agencies (NASA, JAXA, ESA, RSA, etc.) in SHS experiments under microgravity conditions has been increasingly growing. The first SHS experiments during a parabolic flight in Russia and aboard the MIR Space station gave promising results. Similar studies are now being carried out in various countries. The obtained data and assimilated experience have shown that SHS reactions can be used for (a) synthesis of high-porosity materials and regulation of structure formation in combustion products, (b) preparation of skeleton structures by combustion of particles suspended in vacuum, (c) generation of thermal energy, (d) generation of incandescent radiation, and (e) for in-space fabrication and in-situ repair works (welding, joining, cutting, coating, near-net-shape production, etc.). However, the results of the above studies (strongly scattered in the literature) still seem insufficient for elucidating the mechanism of combustion in. Indeed, the experiments were carried out by different researchers for a dozen of systems and for strongly different duration of microgravity (drop towers, parabolic flight of a plane, parabolic flight of a spacecraft, in space stations). No correlation has been made with the available data of SHS studies (oriented largely on practical implementation) in conditions of artificial gravity. In experiments, the combustion wave has enough time to spread over the sample while the structure formation, may not have. This implies that the process of wave propagation should always be identical, irrespective of the type of experimental technique and place of experiment. SHS experiments in space are attractive because (a) of low energy requirements, (b) processing cycle is short, (c) of process simplicity, (d) of versatility (wide range of suitable materials, and (e) the use of in-situ resources possible. To date, SHS experiments has already been performed aboard the International Space Station (ISS). Space technology has been developed for frontier exploration not only around the Earth orbit environment but also to the Moon, Mars, etc.

Ferrites with composition of NiMnxFe1-xO4, (with x = 0 ÷ 1.0) have been synthesized by self-propagating high-temperature synthesis (SHS). The particle size of the synthesized ferrite powder was about 10 nm. Additional heat treatment at 1270 K during 50 min allowed us to obtained product with the single phase composition NiFe2O4. We found out that the increasing of the manganese content (x) increased the lattice constant of the ferrites from 0.833896 nm (x = 0) up to 0.836369 nm (x = 1). The synthesized powder contains two types of ferrite particles that are varied in size and shape. The magnetic properties significantly depend on the microstructure and chemical composition of synthesized ferrites. It has been found that the coercive force Hc increased from 1.75 (x = 0.2) to 2.85 (x = 1). By using of IBSD technology thin film of NiFe2O4 was sputtered on the Si (100) substrate. All sputtered films were X-ray transparent. The structure of ferrite films consisted of agglomerate less than 35 nm. The thickness of the sputtered film was about 600 nm. Additional heat treatment at 770 K during 90 min resulted to homogeneity of the film microstructure. The temperature range 400-750 K corresponds to working temperature range of gas-sensing devices. The ferrite compounds were studied by TOF-SIMS (Time-of-Flight Secondary-Ion-Mass-Spectrometry) for all depth of film. The resistivity R of synthesized film was 39 kΩ. Measurement of gas-sensing sensitivity RCH4/Rair for gas (2%v. CH4) – air mixture showed increase of R up to 12% at the present of methane at 403 K. For further research we plan to replace iron to manganese ions in chemical compounds of ferrite.