Synthesis and characterisation of Ti6Al4V/xTa alloy processed by solid state sintering

ABSTRACT

This work investigates the effect of Ta particle addition into a Ti6Al4V alloy processed by solid state sintering. The volume fraction of Ta ranged between 0 and 30?vol.-%. The sintering kinetics of powder mixes are evaluated by dilatometry. Sintered materials are characterised by SEM and XRD, and their mechanical properties are obtained from microhardness and compression tests. Sintering behaviour and final microstructure are affected by Ta particles, which slow down the densification, lower the temperature of α-to-β phase transition and stabilise the β phase. Mechanical properties, as microhardness, Young’s modulus and yield stress, depend on the microstructure reached after sintering and on the residual porosity. An equation expressing the Young’s modulus of Ti6Al4V/xTa alloy as function of x and porosity is proposed and validated. The materials with at least 20?vol.-% of Ta exhibited a high strength to modulus ratio, which is suitable for orthopaedic implants.     

Mechanical and microstructural properties of titanium/hydroxyapatite functionally graded material fabricated by spark plasma sintering

ABSTRACT

In this article, different functionally graded material specimens were made from titanium powder and hydroxyapatite (HA) submicron particles. The spark plasma sintering method was applied to fabricate the specimens. Two kinds of starting powder mixture were used: mixed powder and ball-milled powder. Percentage of HA was changed from 0 vol.-% to 40 vol.-% in the different number of layers (2, 3 and 5-layer). The effects of the number of the layers and ball-mill process were investigated on microstructure, microhardness, compressive strength and fracture surface. The results show that the grain size has been enhanced by increasing the amount of HA in the layers. In addition, the Vickers microhardness has been first increased by enhancing the percentage of HA, while it has been decreased in the layers with a higher amount of it. Furthermore, the highest compressive strength could be achieved in the five-layer samples. Moreover, specimens with ball-milled powder have higher microhardness and less compressive strength.     

Selective Laser Melting Additive Manufacturing of Ti-Based Nanocomposites: The Role of Nanopowder

The additive manufacturing of bulk-form TiC/Ti nanocomposite parts was performed using Selective Laser Melting (SLM). Two categories of nanopowder, i.e., ball-milled TiC/Ti nanocomposite powder and directly mechanical mixed nano-TiC/Ti powder, were used for SLM. The influences of nanopowder characteristics and laser processing parameters on the densification behavior, microstructural features, and tribological properties of the SLM-processed TiC/Ti nanocomposite parts were studied. The study showed that the densification of TiC/Ti nanocomposite parts was affected by both laser energy density and powder categories. Using an insufficient laser energy density of 0.25 kJ/m lowered SLM densification rate, because of the occurrence of balling effect. An increase in the laser energy density above 0.33 kJ/m produced near fully dense SLM parts. The SLM densification levels of the ball-milled TiC/Ti nanocomposite powder were generally higher than that of the directly mixed nano-TiC/Ti powder. The TiC-reinforcing phase in SLM-processed TiC/Ti parts typically had a lamellar nanostructure with a nanoscale thickness, completely differing from the starting nanoparticle morphology before SLM. The lamellar nanostructure of the TiC reinforcement in SLM-processed ball-milled TiC/Ti nanocomposite parts could be maintained within a wide range of laser energy densities. However, the microstructures of the SLM-processed, directly mixed nano-TiC/Ti powder were sensitive to SLM parameters, and the TiC reinforcement experienced a successive change from the lamellar nanostructure to the relatively coarsened dendritic microstructure as laser energy density increased. A combination of the sufficiently high SLM densification rate and the formation of the nanostructured TiC reinforcement favored the improvement of the tribological property, leading to the considerably low coefficient of friction of 0.22 and wear rate of 2.8 × 10^?16 m³ N^?1 m^?1. The coarsening and resultant disappearance of nanoscale TiC reinforcement in SLM-consolidated directly mixed nano-TiC/Ti powder at a high laser energy density lowered the tribological performance considerably.     

Effect of composition and milling time on mechanical and wear performance of copper–graphite composites processed by powder metallurgy route

Abstract

Copper–graphite (Cu–Gr) composites with 0, 5, 10 and 15 vol.-% graphite were processed via powder metallurgy route. The effect of composition and milling time on mechanical properties and wear resistance were studied. With increase in vol.-% of graphite, there was decrease in hardness of the composites. However, increasing milling time showed significant increase in hardness of the composites. Compressive strength of the composites containing 5 and 10 vol.-% of graphite was found to be 515 and 393 MPa respectively. The wear tests were carried out using a block-on-ring tribometer at a load of 30 N with varying sliding speed. The wear performance of the composites was found to be better with increase in milling time. The worn surfaces were analysed using FESEM. With increase in graphite content from 5 to 15 vol.-%, the coefficient of thermal expansion of the Cu–Gr composites decreased from 14·1 to 12·2×10^?6/°C.     

Effect of C/Ti ratio on the compressive properties and wear properties of the 50 vol.-% submicron-sized TiCx/2014Al composites fabricated by combustion synthesis and hot press consolidation

In this study, in situ 50?vol.-% TiC_x/2014Al composites with different C/Ti molar ratios (0.6, 0.7, 0.8, 0.9 and 1) were successfully produced by the method of combustion synthesis and hot press consolidation. The microstructure and the mechanical properties of the composites were investigated. Microstructure characterisation of the TiC_x/2014Al composites showed relatively uniform distribution of the TiC_x particles with the particle size in the range of 200–900?nm. With the increase of the C/Ti molar ratio, the yield strength (σ_0.2) and the ultimate compression strength (σ_UCS) increased first then decreased, and the fracture strain (ε_f) increased. The σ_0.2, σ_UCS and the abrasive wear resistance of the 50?vol.-% TiC_x/2014Al composites reached the highest value when the value of the C/Ti molar ratio comes to 0.8. The σ_0.2, σ_UCS and ε_f of the 50?vol.-% TiC_x/2014Al composites with the C/Ti molar ratio of 0.8 are 1094?MPa, 1454 and 6.13%, respectively.     

Extraction and permeation of cadmium ions through supported liquid membrane impregnated with mixtures of D2EHPA and M2EHPA

Abstract

The use of an organic carrier consisting of di-(2-ethylhexyl) phosphoric acid (D2EHPA) and mono-(2-ethylhexyl) phosphoric acid (M2EHPA), diluted in kerosene, for separation of cadmium through a supported liquid membrane (SLM) was investigated. The extraction percentage of cadmium and permeability coefficients rose by increasing M2EHPA and feed phase concentration. By increasing the volume percentage of M2EHPA, the permeability coefficient of cadmium increased to a maximum value of 8 cm s^?1 at 1·5 vol.-% declining at higher volume percentages. The permeability of cadmium ions through the SLM decreased with time. The permeation coefficient increased as the initial cadmium concentration increased.

On a étudié l’utilisation d’un support organique consistant d’acide phosphorique di-(2-éthylhexyle) (D2EHPA) et mono-(2-éthylhexyle) (M2EHPA), dilué dans du kérosène, pour la séparation du cadmium à travers une membrane liquide supportée (SLM). Le pourcentage d’extraction du cadmium et les coefficients de perméabilité s’élevaient avec l’augmentation du M2EHPA et de la concentration de la phase d’alimentation. En augmentant le % de volume de M2EHPA, le coefficient de perméabilité du cadmium augmentait à une valeur maximale de 8 cm s^?1 à un volume de 1·5% et déclinait à des % plus élevés du volume. La perméabilité des ions de cadmium à travers la SLM diminuait avec le temps. Le coefficient de perméation augmentait avec l’augmentation de la concentration initiale de cadmium.     

THE FABRICATION AND PROPERTIES OF URANIUM OXIDE–IRON CERMETS

Abstract

Cermets of iron–uranium dioxide, containing up to 30 vol.-% UO₂ have been rolled to rod. Although the cores rolled centrally along the length, the core was distorted in section owing to stiffening of the core relative to the sheath as the temperature dropped during rolling. The UO₂ particles were fragmented during rolling and formed as “stringers” along the direction of rolling, seriously weakening the structure transversely.

By extrusion at 1200° C., cermets containing up to 50 vol.-% UO₂ were satisfactorily fabricated. The extrusion pressure increased sharply above 35 vol.-% of ceramic and when large reductions in area were taken. The extrusion characteristics do not conform to isotropic plastic extrusion nor to a pure viscosity effect; the influence of the dispersed particles on metal flow is explained by a strong interference effect between particles and the metal during flow. The properties of the extruded rods were good; the core density was 90–95% of theoretical, decreasing slightly with increasing ceramic content; there were no obvious directional properties in the core, nor was the ceramic fragmented as in rolling. The characteristic “tail-end defect” of the extrusions was partly corrected by using shaped sealing plugs.     

Hipping after sintering of titanium diboride cermets

Abstract

A new fabrication route, an alternative to glass encapsulated hipping (GEHIP), has been developed to produce dense TiB₂ cermets. Key points of this technique, based on hipping after vacuum sintering (VS + HIP), are the use of Ni₃ (Al,Ti) as binder phase and the selection of the proper amount of additions. The main advantage of VS + HIP with respect to GEHIP is the simplification of the sintering procedure which avoids the glass encapsulation step that makes it more adaptable for industrial use. Successful application of VS + HIP requires a minimum binder content about 10 vol.-% below which a significant hardness reduction is observed owing to the presence of residual porosity as compared with GEHIP. The materials produced by this technique combine low density and high stiffness with high hardness and toughness values, thus giving a set of properties especially attractive for applications where inertial loads are responsible for failure.     

选择性激光熔化制备纯钨块体材料的研究

采用选择性激光熔化技术制备了纯钨块状样品, 研究了激光参数对所制备样品的表面形貌、内部晶粒组织和密度的影响。结果表明, 随着激光能量密度的增加, 样品表面变得光滑, 样品内部孔隙减少, 密度提高。采用功率300 W、扫描速率200 mm?s-1的激光扫描参数制备出了相对密度为97%的纯钨块状样品; 当激光功率提高至350 W时, 由于裂纹增多使样品密度下降; 随着激光输入能量密度的增加, 选择性激光熔化制备的样品内部晶粒方向性变得明显, 且晶粒尺寸增大; 采用扫描策略2 (激光功率200 W, 激光扫描速度200 mm?s-1)进行制备的样品内部孔隙较多, 且孔隙大多沿样品增材制造高度方向呈一条直线分布, 样品内部部分晶粒沿样品增材制造高度方向伸长。     

Effects of powder processing on densification of titanium diboride based cermets

Abstract

The sinterability of TiB₂-Ni₃(Al,Ti) based cermets has been significantly improved by aggressive milling of the starting TiB₂-Ni-TiAl₃ powder mixtures. This technique improves not only liquid spreading by reducing TiAl₃ particle size but also eliminates alumina agglomerates and the associated porosity found after vacuum sintering. Liquid phase sintering of TiB₂-Ni-TiAl₃ powder mixtures involves the presence of Ni based secondary borides at low temperatures (1200°C), which react afterwards with TiAl₃ particles leading to the formation of the final TiB₂-Ni₃(Al,Ti) eutectic liquid. Apart from improving liquid spreading around TiB₂ grains, aggressive milling is also found to disperse alumina agglomerates, which reduces the porosity associated to these particles. By this refined procedure, the amount of binder phase required for full densification of TiB₂ cermets by sinter hipping has been reduced from a previous limit of 16 vol.-% to 10 vol.-%. The hardness of these TiB₂-10 vol.-%Ni₃(Al,Ti) cermets is in the range of ultrafine WC-Co hardmetals in spite of their much coarser microstructure.     

Effect of subsequent Hot Isostatic Pressing on mechanical properties of ASTM F75 alloy produced by Selective Laser Melting

Abstract

The Co-based alloy ASTM (Co – 28.5?wt.-% Cr – 6.3?wt.-% Mo) is widely used for medical implants, e.g. knee prostheses, and is commonly processed by investment casting. Selective laser (SLM) melting is supposed to be an efficient alternative for the production of individually designed knee implants regarding production time and production costs. The mechanical properties, in particular the fatigue strength, of the material have been studied in different states of the material. The mechanical properties of investment casted ASTM F75 and PM-SLM produced ASTM F75 were investigated. The focus in this study was on the PM-SLM material, the specimens were initially produced by selective laser melting and a part of the specimens were further processed by hot isostatic pressing (HIP). The PM-SLM material was mechanically tested in the as-SLM state as well as in the SLM+HIP state. It was found that the mechanical properties of the as-SLM material did not reach the level of the fatigue strength of as cast material. The post-densification treatment by HIP offers distinct improvements regarding the fatigue strength compared to the as-SLM material.     

Densification, Microstructure, and Wear Property of In Situ Titanium Nitride-Reinforced Titanium Silicide Matrix Composites Prepared by a Novel Selective Laser Melting Process

This work presents the densification behavior, microstructural features, microhardness, and wear property of in situ TiN/Ti₅Si₃ composite parts prepared by a novel Selective Laser Melting (SLM) process. The occurrence of balling phenomenon at a low laser energy density combined with a high scan speed and the formation of thermal cracks at an excessive laser energy input generally decreased densification rate. The in situ-formed TiN reinforcing phase experienced a successive morphological change: an irregular polyangular shape—a refined near-round shape—a coarsened dendritic shape, as the applied laser energy density increased. The variations in liquid-solid wettability and intensity of Marangoni convection within laser molten pool accounted for the different growth mechanisms of TiN reinforcement. The TiN/Ti₅Si₃ composite parts prepared under the optimal SLM conditions had a near-full 97.7 pct theoretical density and a uniform microhardness distribution with a significantly increased average value of 1358.0HV_0.3. The dry sliding wear tests revealed that a considerably low friction coefficient of 0.19 without any apparent fluctuation and a reduced wear rate of 6.84 × 10⁻⁵mm³/Nm were achieved. The enhanced wear resistance was attributed to the formation of adherent strain-hardened tribolayer covered on the worn surface.     

Effects of mechanical properties on precipitation hardening stainless steel by selective laser melting,hot isostatic pressing,solid-solution and aging treatments

ABSTRACT

The selective laser melting (SLM) process has gained considerable attention from industry and academia over the recent years. Furthermore, the hot isostatic pressing (HIP) technique has been widely applied as a post-treatment to increase the relative density of the fabricated parts. The main aim of this study is to investigate the effects of porosity elimination and mechanical properties on precipitation hardening stainless steel using SLM, HIP, solid-solution and aging treatments. This study also applied various laser scanning pitches (170, 210 and 250?μm), so that a significant phase transformation occurred between the SLM, HIP, solid-solution and aging treatments. The results showed that the laser scanning pitch was 170?μm, and after HIP, solid-solution and aging treatments the materials possessed optimal mechanical properties. The highest hardness (48.8?±?0.5 HRC) and TRS (2247.0?±?157.8?MPa) could be acquired.     

Dispersion-Strengthened Copper Alloys with Useful Electrical and Mechanical Properties

Abstract

Dispersion-strengthened alloys have been made which combine a high level of tensile strength at temperatures up to at least 600°C with an electrical conductivity better than that of most precipitation-hardened copper alloys. The reverse gel precipitation process has been used to co-precipitate hydroxides which were then selectively reduced in hydrogen, consolidated under an atmosphere of pure argon, and finally hot-extruded to bar. Copper?3 vol.-% zirconia alloys were prepared in which all the particles were <150 nm dia., while copper–1·5 vol.-% thoria and copper–3 vol.-% thoria alloys were prepared with most particles <50 nm dia. Although the dispersion in the Cu–zirconia alloys was somewhat inferior to that obtained in the Cu–thoria alloys, useful properties were obtained. The Cu–zirconia alloys were as strong as the commercial alloy Cu–1 wt.-%Cr at 500°C and twice as strong at 600°C. There was little difference in the strength of a Cu–1·5 vol.-% thoria alloy and the Cu–zirconia alloys but the former was more ductile. The most interesting properties were obtained from Cu–3 vol.-% thoria alloys which exhibited an electrical conductivity in excees of 90% IACS at 20°C and tensile strength five times that of Cu–1%Cr at 600°C, even after annealing at 600°C for 1 h. The Cu–3 vol.-% thoria alloys were readily cold-worked, exhibited exceptional stability, and were resistant to recrystallization up to 900°C. Grain sizes were of the order of 1·5 μm for unalloyed copper, 1 μm for Cu–1·5% thoria, and 0·5 μm for Cu–3% zirconia or Cu–3% thoria. Grain growth was severely restricted by the dispersions.     

Current PM literature for engineers and users

Abstract

Fully dense composite materials of M3/2 tool steel reinforced with 5 and 8 vol.-% of niobium carbide were developed using the powder metallurgy route. The consolidated materials exhibited a fine and uniform microstructure consisting of a fine dispersion of carbide particles in a matrix of ferrite/martensite. The 0·2% yield strength up to 600°C was evaluated in compression. The slight increase observed after reinforcement by NbC particles in as hipped materials suggests that the martensite has the major contribution to the strength. After tempering, the reinforced materials showed a moderate increase in yield stress at room temperature with respect to the unreinforced M3/2. This increase is attributed to reinforcement mechanisms associated with niobium carbide. PM/1175     

Microstructure and mechanical properties of SiC particles reinforced Mg–8Al–1Sn magnesium matrix composites fabricated by powder metallurgy

The new type of Mg–8Al–1Sn (AT81) magnesium matrix composites reinforced with different volume fractions (5, 10, 15, 20, 25 and 30 vol.-%) of SiC particles (average size of 10 μm) was fabricated by powder metallurgy. With the increasing volume fraction of SiC particles (SiC_p), the particles gradually show more homogeneous distribution. Compared with the AT81 alloy, the yield strength (YS) and ultimate compressive strength of the SiC_p/AT81 composites are improved simultaneously. With the increasing SiC_p from 0 to 30 vol.-%, the YS and ultimate compressive strength increase from 69 to 239 MPa and 286 to 385 MPa respectively, while the corresponding fracture strain (ε) decreases from 19·3 to 4·8%. The improvement of the YS and ultimate compressive strength of the SiC_p/AT81 composites benefits from the more homogeneous microstructure due to the increase in the SiC particles.     

选区激光熔化工艺参数对气雾化316L不锈钢粉末成形制品性能的影响

本研究系统考察了激光功率和扫描速度对316L不锈钢粉末选区激光熔化工艺成形熔道、制品微观组织及力学性能的影响,并分析了各类缺陷的形成原因。研究结果表明:在低激光功率和高扫描速度条件下,熔道中出现了大量球状颗粒,这些颗粒之间的空隙恶化了下一层粉末的熔化条件,这正是成形制品中熔道分布混乱以及孔洞、裂纹产生的根本原因,进而导致成形制品力学性能降低;在高激光功率和低扫描速度条件下,熔池快速升温/冷却的热应力作用增强,使得成形制品的熔道交界处也存在孔洞和裂纹等缺陷。在本研究实验条件下,激光功率为350 W,扫描速度为1750 mm/s时,SLM成形制品的力学性能最为优异,其中抗拉强度为731 MPa、屈服强度为638 MPa、断后伸长率为40.0%,致密度为96.27%。     

Sintering parameters and mechanical properties of injection moulded aluminium powder

Abstract

This paper describes the microstructural and mechanical properties of injection moulded aluminium powder. Gas atomised aluminium powder was injection moulded with wax based binder. The critical powder loading for injection moulding was 62·5 vol.-% for feedstock. Binder debinding was performed in solvent and thermal method. After debinding, the samples were sintered at different temperatures and times in high purity N₂. Metallographic studies were conducted to determine the extent of densification and the corresponding microstructural changes. The results show that gas atomised aluminium powder could be sintered to a maximum 96·2% of theoretical density. Maximum density, tensile strength and hardness were obtained when sintered at 650°C for 60 min.     

Effects of TiB2/TiCx ratios on compression properties and abrasive wear resistance of in situ 50 vol.-% (TiB2–TiCx)/Al–Cu composites

Effects of TiB₂/TiC_x ratios on compression properties and abrasive wear resistance of 50?vol.-% (TiB₂–TiC_x)/Al–Cu composites fabricated via the combustion synthesis (CS) method assisted with hot press from the Al–Ti–B₄C system were studied. With decrease in the TiB₂/TiC_x ratio from 3:1 to 1:3, the shape of TiB₂ changed from platelike to clubbed while the size of TiC_x particles increased, which directly led to different mechanical properties. The 50?vol.-% (TiB₂–TiC_x)/Al–Cu composite with the TiB₂/TiC_x ratio of 2:1 exhibited good compression strength without sacrificing the fracture strain, while the composite possessed the highest abrasive wear resistance when the TiB₂/TiC_x ratio was 3:1. The appropriate TiB₂/TiC_x ratio was recommended to be 2:1 in this research.     

Metal Matrix Composites Produced by Spray Codeposition

Abstract

A new technique for producing metal matrix particulate composites, consisting of the spray deposition of the metal matrix and the particles, is described. The deposit is removed from the substrate and hot rolled to produce composite strip for examination and testing. It is shown that up to 36 vol.-% of SiC, Al₂0₃, chilled iron, graphite, and sand particles, and mixtures of these, 75–120 μm in size, can successfully be incorporated in aluminium and Al–5Si alloy matrixes. The friction properties of some of the composites were shown to be particularly promising. High coefficients of friction of ～0·6 were obtainable under dry contact conditions, and these were remarkably constant with time. The friction properties compared very favourably with conventional asbestos based and sintered friction materials which showed lower coefficients of friction that increased with time. PM/0310