Search Results (16)

Multi-principal element alloys (MPEAs) exhibit distinct characteristics compared to conventional single-principal element-based metallic materials, primarily due to their unique design, resulting in intricate microstructural features. Currently, a comprehensive understanding of the fabrication processes, compositional design, and microstructural influence on the tribological and corrosion behavior of multi-component alloys remains limited. While the hardness of MPEAs generally correlates positively with wear resistance, with higher hardness typically associated with improved wear resistance and reduced wear rates, quantitative relationships between these properties are not well established. In this study, the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was selected as a model system. A homogeneous Al₁₀Cr₁₇Fe₂₀NiV₄ alloy was successfully synthesized via mechanical alloying followed by spark plasma sintering (SPS). To further investigate the correlation between hardness and wear rate, varying concentrations of alumina nanoparticles were incorporated into the alloy matrix as a reinforcing phase. The results revealed that the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy exhibited a single-phase face-centered cubic (FCC) structure, which was maintained with the addition of alumina nanoparticles. The hardness of the Al₁₀Cr₁₇Fe₂₀NiV₄ alloy without nano-alumina was 727 HV, with a corresponding wear rate of 2.9 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The incorporation of nano-alumina increased the hardness to 823 HV, and significantly reduced the wear rate to 1.6 × 10⁻⁴ mm³·N⁻¹·m⁻¹, representing a 45% reduction. The Al₂O₃ nanoparticles effectively mitigated alloy wear through crack passivation and matrix strengthening; however, excessive addition reversed this effect due to the agglomeration-induced brittleness and thermal mismatch. The quantitative relationship between hardness (HV) and wear rate (W) was determined as W = 2348 e^(−0.006HV). Such carefully bounded empirical relationships, as demonstrated in studies of cold-formed materials and dental enamel, remain valuable tools in applied research when accompanied by explicit scope limitations. Full article

In order to investigate the most extreme conditions in which materials potentially applicable in reusable thermal shields can be operated, ultra-high-temperature ZrB₂ ceramics with 20 vol.% MoSi₂ were prepared using two different techniques, cold isostatic pressing (CIP) and robocasting (RC, an additive manufacturing technique), followed by consolidation using pressureless spark plasma sintering (SPS). The oxidation behavior of the resulting materials was analyzed in low-pressure dissociated air at three different temperatures, namely 1800, 2000 and 2200 K. Using XRD and surface and cross-section SEM (coupled with EDS), zirconia was found to form at all three temperatures, while silica was only present at 1800 K, with gaseous SiO forming at a higher temperature. The elaboration technique influences the density of the ceramic, and less dense materials undergo deeper oxidation. This investigation suggests that 2000 K is already beyond the maximum temperature threshold at which damage to ceramics is limited by the formation of protective silica. This study confirms that the selected material is a promising candidate for thermal protection applications. Full article

Our study is focused on optimizing the synthesis conditions for the in situ oxidation of Fe particles to produce Fe@Fe₃O₄ core–shell powder and preparation via co-precipitation of ZnFe₂O₄ nanoparticles to produce Fe@Fe₃O₄/ZnFe₂O₄ soft magnetic composites (SMC) through a hybrid cold-sintering/spark plasma-sintering technique. XRD and FTIR measurements confirmed the formation of a nanocrystalline oxide layer on the surface of Fe powder and the nanosized nature of ZnFe₂O₄ nanoparticles. SEM-EDX investigations revealed that the oxidic phase of our composite was distributed on the surface of the Fe particles, forming a quasi-continuous matrix. The DC magnetic characteristics of the composite compact revealed a saturation induction of 0.8 T, coercivity of 590 A/m, and maximum relative permeability of 156. AC magnetic characterization indicated that for frequencies higher than 1 kHz and induction of 0.1 T, interparticle eddy current losses dominated due to ineffective electrical insulation between neighboring particles in the composite compact. Nevertheless, the magnetic characteristics obtained in both DC and AC magnetization regimes were comparable to those reported for cold-sintered Fe-based SMCs. Full article

Two sorts of tablets were manufactured from ball-milled powder (aluminum scrap and copper) by cold pressing and spark plasma sintering. Their microstructure, phase, and elemental compositions were investigated via scanning electron microscopy, X-ray diffraction analysis, and energy-dispersive X-ray spectroscopy. New phases, Al₂Cu and MgCuAl₂, were detected in the samples. Their microstructure was formed by welded scrap particles, the intermetallides, and Cu-rich regions located majorly along ‘interparticle boundaries’ and, to a lesser extent, within small, micro- and nanosized ‘intraparticle spots’. The tablets were sealed with adhesive, so only the top surface was exposed to the environment, and tested in a chlorine aqueous solution for hydrogen generation performance. For both sample sorts, hydrogen yields of nearly 100% were achieved. The sintered tablets reacted faster than the cold-pressed ones: at 60, 70, and 80 °C, their entire ‘conversion into hydrogen’ took ~80, 40, and 30 min. vs. ~220, 100, and 70 min. The experimental kinetic curves were fitted with a contracting geometry equation, and those for the sintered samples were approximated with higher precision. The key effect of the additive was to enhance hydrogen evolution through the galvanic corrosion of Al in the regions adjacent to the intermetallic inclusions and Cu-rich spots. Full article

A developing energy-saving approach of cold sintering in a pure aqueous medium was applied to the preparation of α-Al₂O₃ ceramics and performed on spark plasma sintering equipment. The initial γ-Al(OH)₃ and γ-AlOOH powders and the cold-sintered ceramics were studied by X-ray diffraction analysis, infrared spectroscopy, thermal analysis, and scanning electron microscopy to reveal the chemical and structural transformations they experienced during the cold sintering. At 450 °C and 70 MPa, initially γ-AlOOH transformed into a fragile α-Al₂O₃ material. Porous α-Al₂O₃ ceramics with about 60% porosity were obtained after cold sintering of γ-Al(OH)₃ in the same conditions combined with subsequent annealing at 1250 °C for 3 h. The role of water molecules in the studied processes was considered as the enhancement of structural mobility in the cold-sintered material due to its reversible hydroxylation similar to earlier investigated supercritical water actions on the precursors during α-Al₂O₃ formation. Further improvement of the cold sintering setup and regimens would open prospects in α-Al₂O₃ ceramics manufacturing by an ecologically benign route. Full article

Hydroxyapatite is a widely used material used for the bioactivation of an implant’s surface. A promising hydroxyapatite coating approach is the kinetic deposition of powder particles. The possibility of solid-state deposition improvement through the merging of Aerosol Deposition and Low Pressure Cold Spraying techniques is a promising prospect for improving the deposition efficiency and the quality of coatings. The objective of the paper is to study the possibilities of hydroxyapatite coating structure modification through changes in the coating process and post-heat treatment. The novel Aerosol Cold Spraying system joining Low Pressure Cold Spraying and Aerosol Deposition was used for the deposition of coatings. The coating’s post-processing was conducted using two techniques: Spark Plasma Sintering and Pressureless Sintering. The coating’s structure was examined using scanning, transmission, and light microscopy, and X-ray diffraction. Substrate–coating bond strength was assessed using a tensile test. Homogenous buildup using Aerosol Cold Spraying of hydroxyapatite was achieved. Various pores and microcracks were visible in the sprayed coatings. The deposition process and the thermal post-processing did not lead to significant degradation of the hydroxyapatite phase. As a result of the Spark Plasma Sintering and Pressureless Sintering at 800 °C, an increase in tensile adhesion bond strength and crystal size was obtained. Full article

The new generation of high-frequency and high-efficiency motors has high demands on the soft magnetic properties, mechanical properties and corrosion resistance of its core materials. Bulk amorphous and nanocrystalline alloys not only meet its performance requirements but also conform to the current technical concept of integrated forming. At present, spark plasma sintering (SPS) is expected to break through the cooling-capacity limitation of traditional casting technology with high possibility to fabricate bulk metallic glasses (BMGs). In this study, Fe₈₄Si₇B₅C₂Cr₂ soft magnetic amorphous powders with high sphericity were prepared by a new atomization technology, and its characteristic temperature was measured by DSC to determine the SPS temperature. The SEM, XRD, VSM and universal testing machine were used to analyze the compacts at different sintering temperatures. The results show that the powders cannot be consolidated by cold pressing (50 and 500 MPa) or SPS temperature below 753 K (glass transition temperature T_g = 767 K), and the tap density is only 4.46 g·cm⁻³. When SPS temperature reached above 773 K, however, the compact could be prepared smoothly, and the density, saturation magnetization, coercivity and compressive strength of the compacts increased with the elevated sintering temperature. In addition, due to superheating, crystallization occurred even when the sintering temperature was lower than 829 K (with the first crystallization onset temperature being T_x1 = 829 K). The compact was almost completely crystallized at 813 K, resulting in a sharp increase in the coercivity of the compact from 55.55 A·m⁻¹ at 793 K to 443.17 A·m⁻¹. It is noted that the nanocrystals kept growing in size as the temperature increased to 833 K, which increased the coercivity remarkably but showed an enhanced saturation magnetization. Full article

The great prospects for introducing the cold sintering process (CSP) into industry determine the importance of finding approaches to reduce the processing time and mechanical pressure required to obtain dense ceramics using CSP. The introducing zinc acetate into the initial ZnO powder of methods, such as impregnation, thermovapor autoclave treatment (TVT), and direct injection of an aqueous solution into a die followed by cold sintering process using a spark plasma sintering unit, was studied. The effect of the introduction methods on the density and grain size of sintered ceramics was analyzed using SEM, dynamic light scattering, IR spectroscopy, and XRD. The impregnation method provides sintered samples with high relative density (over 0.90) and significant grain growth when sintered at 250 °C with a high heating rate of 100 °C/min, under a uniaxial pressure of 80 MPa in a vacuum, and a short isothermic dwell time (5 min). The TVT and aqueous solution direct injection methods showed lower relative densities (0.87 and 0.76, respectively) of CSP ZnO samples. Finally, the development of ideas about the processes occurring in an aqueous medium with CSP and TVT, which are subject to mechanical pressure, is presented. Full article

Glasses, which date back to about 2500 BC, originated in Mesopotamia and were later brought to Egypt in approximately 1450 BC. In contrast to the long-range order materials (crystalline materials), the atoms and molecules of glasses, which are noncrystalline materials (short-range order) are not organized in a definite lattice pattern. Metallic glassy materials with amorphous structure, which are rather new members of the advanced materials family, were discovered in 1960. Due to their amorphous structure, metallic glassy alloys, particularly in the supercooled liquid region, behave differently when compared with crystalline alloys. They reveal unique and unusual mechanical, physical, and chemical characteristics that make them desirable materials for many advanced applications. Although metallic glasses can be produced using different techniques, many of these methods cannot be utilized to produce amorphous alloys when the system has high-melting temperature alloys (above 1500 °C) and/or is immiscible. As a result, such constraints may limit the ability to fabricate high-thermal stable metallic glassy families. The purpose of this research is to fabricate metallic glassy (Zr₇₀Ni₂₅Al₅)_100-xW_x (x; 0, 2, 10, 20, and 35 at. %) by cold rolling the constituent powders and then mechanically alloying them in a high-energy ball mill. The as-prepared metallic glassy powders demonstrated high-thermal stability and glass forming ability, as evidenced by a broad supercooled liquid region and a high crystallization temperature. The glassy powders were then consolidated into full-dense bulk metallic glasses using a spark plasma sintering technique. This consolidation method did not result in the crystallization of the materials, as the consolidated buttons retained their short-range order fashion. Additionally, the current work demonstrated the capability of fabricating very large bulk metallic glassy buttons with diameters ranging from 20 to 50 mm. The results indicated that the microhardness of the synthesized metallic glassy alloys increased as the W concentration increased. As far as the authors are aware, this is the first time this metallic glassy system has been reported. Full article

During nanoindentation tests, the load-displacement curve is used for estimating mechanical properties, while an indent image obtained through atomic force microscopy (AFM) is used for studying deformation of a material. We present a computational platform for developing artificial intelligence-based models for predicting indentation depth (load-displacement curve) and AFM image as a function of test parameters like maximum applied load, loading rate, and holding time. A user can directly use machine generated data in text (.txt) and hierarchical data format (HDF, hdf) format for developing the AI-based models for indentation depth and AFM image, respectively. The software was tested on three different coatings/materials for indentation depth: heat-treated (HT) sample of cold sprayed aluminum-based bulk metallic glass (Al-BMG) coating, carbon nanotube reinforced aluminum composite (Al-5CNT) coating, and spark-plasma-sintered hydroxyapatite (SPS HA) sample. For AFM imaging, a heat-treated (HT) sample of cold sprayed aluminum-based bulk metallic glass (Al-BMG) coating was considered. Correlation or R-values are close to 1 for all the models developed in this work. Predicted load-displacement curve and AFM image are in good agreement with the experimental findings. Our approach will be helpful in virtual simulation of load-displacement curves and AFM indent images for a large number of new test parameters, thus significantly reducing the number of indents needed for characterizing/analyzing a material. Full article

Spark plasma sintering (SPS) has gained recognition in the last 20 years for its rapid densification of hard-to-sinter conventional and advanced materials, including metals, ceramics, polymers, and composites. Herein, we describe the unconventional usages of the SPS technique developed in the field. The potential of various new modifications in the SPS technique, from pressureless to the integration of a novel gas quenching system to extrusion, has led to SPS’ evolution into a completely new manufacturing tool. The SPS technique’s modifications have broadened its usability from merely a densification tool to the fabrication of complex-shaped components, advanced functional materials, functionally gradient materials, interconnected materials, and porous filter materials for real-life applications. The broader application achieved by modification of the SPS technique can provide an alternative to conventional powder metallurgy methods as a scalable manufacturing process. The future challenges and opportunities in this emerging research field have also been identified and presented. Full article

Copper-graphite composites were prepared by spark plasma sintering (SPS) with copper powder and copper-coated graphite powder. The effect of particle size of raw material powder on the current-carrying friction properties of copper-graphite composites was studied. The results show that the friction coefficient of the composites decreased with the decrease of the particle size of copper-coated graphite powder, the friction coefficient of the composites increased with the decrease of the particle size of the copper powder, the wear rate of the composites increased with the decrease of the particle size of the copper-coated graphite powder, and the wear rate of the composites increased significantly with the decrease of the particle size of the copper-coated graphite powder. The current carrying properties of composites with different particle size ratios and QCr0.5 pairs are good and fluctuate little. The current-carrying friction properties of 150 μm copper powder and 75 μm copper-coated graphite powder were found to be the best. The wear surface could be divided into mechanical wear area and arc erosion area. The main area of arc erosion was less than 15% of the total area, and it was mainly distributed in the friction outlet area. The main forms of mechanical wear included furrow, rolling deformation, cold welding, and tearing, among other forms. Graphite film was formed on the surface. The surface quality of the composite prepared by 150 μm copper powder and 75 μm copper-coated graphite powder was the best, the Sa was 3.22 μm, rolling deformation was the most adequate, no large tear pit and furrow appeared, and the carbon content on the worn surface was much higher than that in the composite. The behavior of arc erosion was mainly melting and splashing, and the particle size of the original powder had little effect on it. Full article

Crystalline ceramics are intensively investigated as effective materials in various nuclear energy applications, such as inert matrix and accident tolerant fuels and nuclear waste immobilization. This paper presents an analysis of the current status of work in this field of material sciences. We have considered inorganic materials characterized by different structures, including simple oxides with fluorite structure, complex oxides (pyrochlore, murataite, zirconolite, perovskite, hollandite, garnet, crichtonite, freudenbergite, and P-pollucite), simple silicates (zircon/thorite/coffinite, titanite (sphen), britholite), framework silicates (zeolite, pollucite, nepheline /leucite, sodalite, cancrinite, micas structures), phosphates (monazite, xenotime, apatite, kosnarite (NZP), langbeinite, thorium phosphate diphosphate, struvite, meta-ankoleite), and aluminates with a magnetoplumbite structure. These materials can contain in their composition various cations in different combinations and ratios: Li–Cs, Tl, Ag, Be–Ba, Pb, Mn, Co, Ni, Cu, Cd, B, Al, Fe, Ga, Sc, Cr, V, Sb, Nb, Ta, La, Ce, rare-earth elements (REEs), Si, Ti, Zr, Hf, Sn, Bi, Nb, Th, U, Np, Pu, Am and Cm. They can be prepared in the form of powders, including nano-powders, as well as in form of monolith (bulk) ceramics. To produce ceramics, cold pressing and sintering (frittage), hot pressing, hot isostatic pressing and spark plasma sintering (SPS) can be used. The SPS method is now considered as one of most promising in applications with actual radioactive substances, enabling a densification of up to 98–99.9% to be achieved in a few minutes. Characteristics of the structures obtained (e.g., syngony, unit cell parameters, drawings) are described based upon an analysis of 462 publications. Full article

Tungsten fibre nets reinforced tungsten composites (W_f/W) containing four net layers were fabricated by spark plasma sintering (SPS), hot pressing (HP) and cold rolling after HP (HPCR), with the weight fraction of fibres being 17.4%, 10.5% and 10.5%, respectively. The relative density of the HPCRed samples is the highest (99.8%) while that of the HPed composites is the lowest (95.1%). Optical and scanning electron microscopy and electron back scattering diffraction were exploited to characterize the microstructure, while tensile and hardness tests were used to evaluate the mechanical properties of the samples. It was found that partial recrystallization of fibres occurred after the sintering at 1800 °C. The SPSed and HPed W_f/W composites begin to exhibit plastic deformation at 600 °C with tensile strength (TS) of 536 and 425 MPa and total elongation at break (TE) of 11.6% and 23.0%, respectively, while the HPCRed W_f/W composites exhibit plastic deformation at around 400 °C. The TS and TE of the HPCRed W_f/W composites at 400 °C are 784 MPa and 8.4%, respectively. The enhanced mechanical performance of the W_f/W composites over the pure tungsten can be attributed to the necking, cracking, and debonding of the tungsten fibres. Full article

A new generation of alloys, which rely on a combination of various strengthening mechanisms, has been developed for application in molten salt nuclear reactors. In the current study, a battery of dispersion and precipitation-strengthened (DPS) NiMo-based alloys containing varying amounts of SiC (0.5–2.5 wt %) were prepared from Ni-Mo-SiC powder mixture via a mechanical alloying (MA) route followed by spark plasma sintering (SPS) and rapid cooling. Neutron Powder Diffraction (NPD), Electron Back Scattering Diffraction (EBSD), and Transmission Electron Microscopy (TEM) were employed in the characterization of the microstructural properties of these in-house prepared NiMo-SiC DPS alloys. The study showed that uniformly-dispersed SiC particles provide dispersion strengthening, the precipitation of nano-scale Ni₃Si particles provides precipitation strengthening, and the solid-solution of Mo in the Ni matrix provides solid-solution strengthening. It was further shown that the milling time has significant effects on the microstructural characteristics of these alloys. Increased milling time seems to limit the grain growth of the NiMo matrix by producing well-dispersed Mo₂C particles during sintering. The amount of grain boundaries greatly increases the Hall–Petch strengthening, resulting in significantly higher strength in the case of 48-h-milled NiMo-SiC DPS alloys compared with the 8-h-milled alloys. However, it was also shown that the total elongation is considerably reduced in the 48-h-milled NiMo-SiC DPS alloy due to high porosity. The porosity is a result of cold welding of the powder mixture during the extended milling process. Full article