Wire electrical discharge machinable SiC with GNPs and GO as the electrically conducting filler

SiC based composites filled with graphene nano-platelets (GNPs) or graphene oxide (GO) prepared by rapid hot-pressing exhibit sufficient electrical conductivity for their machinability by wire electro-discharge machining (WEDM). Composites microstructure anisotropy caused by graphene alignment as a consequence of rapid hot pressing was confirmed by measuring of electrical conductivity and thermal diffusivity. Electrical conductivity increased significantly with increased weight fraction of graphene in both measured directions. Highest value of 2031 S/m was obtained for composites with 15 wt. % of GNPs in parallel direction and only 1246 S/m in perpendicular direction to aligned GNPs. Thermal diffusivity is 63.3 mm²/s in parallel and only 23.3 mm²/s in perpendicular direction. The increase of the electrical conductivity has resulted in successful WEDM. The MRR was almost doubled when the filler concentration increased from 5 wt. % GNPs/GO to 15 wt. % GNPs. At the same time, the surface roughness decreased.     

Electrical discharge machining of B4C-TiB2 composites

The interrelationships between the microstructure and electrical discharge machining (EDM) behaviour of B₄C-TiB₂ composites with respectively 30, 40 and 60 vol.% TiB₂ are investigated. Special attention was given to the influence of the grain size on the EDM behaviour by producing composites with an ultrafine TiB₂ phase using in situ synthesis during PECS. The experimental work revealed that 40 vol.% of TiB₂ results in an optimal material removal rate while the surface roughness for rough cut EDM decreases with increasing TiB₂ content. The finer microstructure of the ultrafine composite shows higher MRR's and lower R_a values than the commercial powder based composites. The major material removal mechanism for the PECS based composites was melting. The 3 point bending strength of all composites after grinding, EDM rough cut and EDM finish cut was not statistically different and about 800 MPa. The EDM recast layer was analysed by X-ray photoelectron spectroscopy.     

Highly electrically and thermally conductive silicon carbide-graphene composites with yttria and scandia additives

Dense silicon carbide/graphene nanoplatelets (GNPs) and silicon carbide/graphene oxide (GO) composites with 1 vol.% equimolar Y₂O₃–Sc₂O₃ sintering additives were sintered at 2000 °C in nitrogen atmosphere by rapid hot-pressing technique. The sintered composites were further annealed in gas pressure sintering (GPS) furnace at 1800 °C for 6 h in overpressure of nitrogen (3 MPa). The effects of types and amount of graphene, orientation of graphene sheets, as well as the influence of annealing on microstructure and functional properties of prepared composites were investigated. SiC-graphene composite materials exhibit anisotropic electrical as well as thermal conductivity due to the alignment of graphene platelets as a consequence of applied high uniaxial pressure (50 MPa) during sintering. The electrical conductivity of annealed sample with 10 wt.% of GNPs oriented parallel to the measuring direction increased significantly up to 118 S·cm⁻¹. Similarly, the thermal conductivity of composites was very sensitive to the orientation of GNPs. In direction perpendicular to the GNPs the thermal conductivity decreased with increasing amount of graphene from 180 W·m⁻¹ K⁻¹ to 70 W·m⁻¹ K⁻¹, mainly due to the scattering of phonons on the graphene – SiC interface. In parallel direction to GNPs the thermal conductivity varied from 130 W·m⁻¹ K⁻¹ up to 238 W·m⁻¹ K⁻¹ for composites with 1 wt.% of GO and 5 wt.% of GNPs after annealing. In this case both the microstructure and composition of SiC matrix and the good thermal conductivity of GNPs improved the thermal conductivity of composites.     

Exceptional micromachining performance of silicon carbide ceramics by adding graphene nanoplatelets

The electrical discharge machining (EDM) performance of silicon carbide (SiC) ceramics containing graphene nanoplatelets (GNPs) is investigated for the first time. Under fine machining conditions, the material removal rate (MRR) dramatically increases up to 186% when 20 vol.% of GNPs are added to SiC ceramics, leading to reductions on the electrode wear rate of 132%. The EDMed nanocomposites exhibit surface roughness ≤ 0.8 μm. This outstanding EDM response of the graphene nanocomposites as compared to monolithic SiC is explained by their enhanced transport properties, establishing a direct dependence of MRR with the electrical conductivity. EDM performance of the nanocomposites also depends on the testing direction for materials with low GNPs connectivity (≤ 10 vol.%). Melting/evaporation are the main removal mechanisms, thermal spalling also operating for low thermal conducting materials. The employ of EDM on SiC/graphene nanocomposites allows machining microparts with a fine dimensional precision, opening new opportunities for SiC-based microcomponents.     

Synergistic effects of TiB2 and graphene nanoplatelets on the mechanical and electrical properties of B4C ceramic

Monolithic B₄C, B₄C–TiB₂, and B₄C–TiB₂–graphene nanoplatelets (GNPs) were fabricated by hot pressing (HP) at 1900 °C for 1 h under an axial pressure of 30 MPa. The microstructures and mechanical and electrical properties of the B₄C composites were investigated. The results show that the GNPs are distributed homogeneously in B₄C-based ceramic composites. Compared with monolithic B₄C, the TiB₂–GNPs-containing B₄C composite exhibits an approximately 68 % increase in flexural strength and a 169 % increase in fracture toughness due to the synergistic effects of TiB₂ particles and GNPs. The toughening mechanisms mainly include TiB₂ crack deflection, crack branching, transgranular fracture and GNPs crack deflection, crack bridging, and GNPs pull-out. Additionally, the electrical conductivity of the B₄C composite reinforced with dual fillers is three orders of magnitude higher than that of monolithic B₄C due to the establishment of a conductive network. The addition of GNPs can efficiently connect the isolated conductive TiB₂ particles in the B₄C matrix and provides an additional channel for electron migration.     

The effects of in-situ formed phases on the microstructure,mechanical properties and electrical conductivity of spark plasma sintered B4C containing Y2O3

B₄Cs without additive and 5, 10 and 15 wt % Y₂O₃ containing B₄Cs were produced by using spark plasma sintering (SPS) technique at different temperatures such as 1820, 1930 and 2030 °C and the effects of in-situ formed phases on the mechanical properties and electrical conductivity of B₄C were investigated. Microstructural investigations showed that the YB₄ phase was formed at 1820 °C and the YB₆ phase at 1930 °C. The hardness values of B₄C-YB₄ composites were higher than the value of B₄C sintered at 1820 °C while lower than that of sintered at 2030 °C. The fracture toughness steadily increased with increasing Y₂O₃ content. The electrical conductivity of B₄C sintered at 2030 °C increased by ～ 40 % with the contribution of in-situ formed YB₄ phase. Compared to B₄C-YB₄, B₄C-YB₆’s hardness was higher, while its fracture toughness and electrical conductivity were lower.     

Synthesis and properties of conductive B4C ceramic composites with TiB2 grain network

High electrical resistance and low fracture toughness of B₄C ceramics are 2 of the primary challenges for further machining of B₄C ceramics. This report illustrates that these 2 challenges can be overcome simultaneously using core‐shell B₄C‐TiB₂&TiC powder composites, which were prepared by molten‐salt method using B₄C (10 ± 0.6 μm) and Ti powders as raw materials without co‐ball milling. Finally, the near completely dense (98%) B₄C‐TiB₂ interlayer ceramic composites were successfully fabricated by subsequent pulsed electric current sintering (PECS). The uniform conductive coating on the surface of B₄C particles improved the mass transport by electro‐migration in PECS and thus enhanced the sinterability of the composites at a comparatively low temperature of 1700°C. The mechanical, electrical and thermal properties of the ceramic composites were investigated. The interconnected conductive TiB₂ phase at the grain boundary of B₄C significantly improved the properties of B₄C‐TiB₂ ceramic composites: in the case of B₄C‐29.8 vol% TiB₂ composite, the fracture toughness of 4.38 MPa·m^1/2, the electrical conductivity of 4.06 × 10⁵ S/m, and a high thermal conductivity of 33 W/mK were achieved.     

Material removal mechanisms by EDM of zirconia reinforced MWCNT nanocomposites

Several composites of tetragonal zirconia polycrystals doped with 3 mol% yttria (3Y-TZP) and multiwalled carbon nanotubes (MWCNT) with concentrations from 0.5 to 4 wt% CNT were processed, spark plasma sintered, and characterised for a wide range of mechanical, electrical and thermal properties. In particular, a strong increase in electrical conductivity at room temperature was found with only 0.5 wt% CNT. However, the thermal conductivity was decreasing with increasing CNT content. Electrical discharge machining (EDM) using die sinking was carried out using the composites of 1 and 2 wt% CNT as workpieces. It was shown that both compositions could be successfully machined by EDM. The surface integrity and the subsurface were studied by SEM/FIB in order to determine the material removal mechanisms, which were found to be associated to spalling and melting/evaporation. Raman Spectroscopy was used to evaluate the damage of CNTs after EDM.     

Microstructure and mechanical properties of boron carbide/graphene nanoplatelets composites fabricated by hot pressing

In this study, boron carbide (B₄C)-graphene nanoplatelets (GNPs) composites, with enhanced strength and toughness, were fabricated by hot pressing at 1950 °C under a pressure of 30 MPa for 1 h. Microstructure analysis revealed that the GNPs are homogenously dispersed within the B₄C matrix. Raman spectroscopy and electron microscopy showed the orientation of the GNPs in the composites. The effects of the amount of GNPs on the microstructure and mechanical properties of the composites were also investigated. The optimal mechanical properties were achieved using 1 wt% GNPs. The relative density, Vickers hardness, flexure strength, and fracture toughness of the B₄C-GNPs composite ceramic were found to be 99.12%, 32.8 GPa, 508 MPa, and 4.66 MPa m^1/2, respectively. The main toughening mechanisms included crack deflection in three dimensions, GNPs pull-out, and crack bridging. The curled and semi-wrapped GNPs encapsulated individual B₄C grains to resist GNPs pull-out and to deflect propagating cracks.     

Reaction-formed W2B5/C composites with high performance

Highly densified W₂B₅/C composites with W₂B₅ content from 30 to 70 vol% were fabricated by reaction hot pressing of the powder mixture of B₄C, WC and carbon black. The reaction products were identified by XRD analysis to consist of only W₂B₅ and carbon, regardless of carbon content. The reaction formed composites have excellent mechanical properties (the maximum flexural strength and fracture toughness of 786 MPa and 8.9 MPa m^1/2 respectively), electrical conductivity (the highest electrical conductivity of 1.64 × 10⁶ Ω⁻¹ m⁻¹), and resistance to both wear and oxidation because of the presence of the plate-like W₂B₅ grains. In this paper, the preparation, microstructure and properties of this new composite are investigated, and the strengthening, toughening, conduction mechanisms are discussed.     

The effect of graphene nanoplatelets on the thermal and electrical properties of aluminum nitride ceramics

The thermal conductivity (κ) of AlN (2.9 wt.% of Y₂O₃) is studied as a function of the addition of multilayer graphene (from 0 to 10 vol.%). The κ values of these composites, fabricated by spark plasma sintering (SPS), are independently analyzed for the two characteristic directions defined by the GNPs orientation within the ceramic matrix; that is to say, perpendicular and parallel to the SPS pressing axis. Conversely to other ceramic/graphene systems, AlN composites experience a reduction of κ with the graphene addition for both orientations; actually the decrease of κ for the in-plane graphene orientation results rather unusual. This behavior is conveniently reproduced when an interface thermal resistance is introduced in effective media thermal conductivity models. Also remarkable is the change in the electrical properties of AlN becoming an electrical conductor (200 S m⁻¹) for graphene contents above 5 vol.%.     

Fabrication of toughened B4C composites with high electrical conductivity using MAX phase as a novel sintering aid

MAX phase Ti₃AlC₂ was chosen as a novel sintering aid to prepare electrically conductive B₄C composites with high strength and toughness. Dense B₄C composites can be obtained at a hot-pressing temperature as low as 1850 °C with 15 vol% Ti₃AlC₂. The enhanced sinterability was mainly ascribed to the in situ reactions between B₄C and Ti₃AlC₂ as well as the liquid phase decomposed from Ti₃AlC₂. Both the Vickers hardness and fracture toughness increase with increasing Ti₃AlC₂ amount, and high hardness and toughness values of 28.5 GPa and 7.02 MPa m^−1/2 respectively were achieved for B₄C composites sintered with 20 vol% Ti₃AlC₂ at 1900 °C. Crack deflection by homogenously distributed TiB₂ particles was identified as the main toughening mechanism. Besides, B₄C composites sintered with Ti₃AlC₂ show significantly improved electrical conductivity due to the percolation of highly conductive TiB₂ phase, which could enhance the machinability of B₄C composites largely by allowing electrical discharge machining.     

Mechanical,electrical properties and microstructures of hot-pressed B4C-WB2 composites

In this paper, dense B₄C-WB₂ composites were fabricated at 1950 °C using B₄C and WB₂ as raw materials via a hot press method. The phase composition, microstructures and mechanical properties of the B₄C-WB₂ composites with different B₄C volume fraction were studied. The obtained 68.7 vol%B₄C-WB₂ composites demonstrated good comprehensive properties with high flexural strength of 696 MPa, superior hardness of 34.8 GPa, and acceptable fracture toughness of 3.3 MPa m^1/2. The high flexural strength mainly resulted from the pinning effect of preferentially oriented strip-shape WB₂ grains and clean grain interfaces between B₄C and WB₂ phases. The toughening mechanism of the B₄C-WB₂ composites was associated with the interfacial residual stress induced by the mismatch of thermal expansion coefficient. In addition, the B₄C-WB₂ composites demonstrated good electrical conductivity (3.3 × 10⁵ S/m) with a low density of 5.589 g/cm³, making them of potential interest for cutting tools and armor protection applications.     

Boron carbide/graphene platelet ceramics with improved fracture toughness and electrical conductivity

Boron carbide/graphene platelet (B₄C/GPLs) composites have been prepared with a different weight percent of GPLs as sintering additive and reinforcing phase, hot pressed at 2100 °C in argon. The influence of the GPLs addition on fracture toughness (K_IC) and electrical conductivity was investigated. Single Edge V-Notched Beam (SEVNB) method was used for fracture toughness measurements and the four-point Van der Pauw method for electrical conductivity measurements. With increasing amount of GPLs additives, the fracture toughness increased due to the activated toughening mechanisms in the form of crack deflection, crack bridging, crack branching and graphene sheet pull-out. The highest fracture toughness of 4.48 MPa.m^1/2 was achieved at 10 wt.% of GPLs addition, which was ∼50% higher than the K_IC value of the reference material. The electrical conductivity increased with GPLs addition and reached the maximum value at 8 wt.% of GPLs, 1.526 × 10³ S/m in the perpendicular and 8.72 × 10² S/m in the parallel direction to the hot press direction, respectively.     

The effect of different GNPs addition on the electrical conductivities and percolation thresholds of the SiAlON matrix composites

Insulating SiAlON ceramics may become electrically conductive with the addition of a conductive phase such as GNPs and can be used more widely. However, the differences in the properties of the used GNPs significantly affect the amount of electrical conductivity that they provide to the matrix. In this study, four different GNPs with different properties such as lateral dimension, thickness and aspect ratio were added to SiAlON in the amount of 1.5, 2, 3 and 4 wt. % and the effects of different properties on the conductivity of composites were investigated. The thinnest GNPs with largest dimension and aspect ratio among the used GNPs provided the highest electrical conductivity and lowest percolation thresholds to SiAlON. The decrease in dimension, aspect ratios and the increase in thickness decreased the electrical conductivity of GNPs. Composites exhibited anisotropic behavior with better conductivity and percolation threshold values in the in-plane direction than through-plane direction.     

Anisotropy of functional properties of SiC composites with GNPs,GO and in-situ formed graphene

This paper reports on anisotropy of functional properties of different silicon carbide-graphene composites due to preferential orientation of graphene layers during sintering. Dense silicon carbide/graphene nanoplatelets (SiC/GNPs) and silicon carbide/graphene oxide (SiC/GO) composites were sintered in the presence of yttria (Y₂O₃) and alumina (Al₂O₃) sintering additives at 1800 °C in vacuum by the rapid hot pressing (RHP) technique. It is found that electrical conductivity of SiC/GNPs and SiC/GO composites increases significantly in the perpendicular direction to the RHP pressing axis, reached up to 1775 S/m in the case of SiC/GO (for 3.15 wt.% of rGO). Also, thermal diffusivity was found to increase slightly by the addition of GNPs in the SiC/GNPs composites in the perpendicular direction to the RHP pressing axis. But, in the parallel direction, the addition of GNPs showed a negative effect. The formation of graphene domains was observed in reference sample SiC-Y₂O₃-Al₂O₃ sintered by RHP, without any addition of graphene. Their presence was confirmed indirectly by increasing electrical conductivity about three orders of magnitude in comparison to the reference sample sintered by conventional hot press (HP). Raman, SEM and TEM analysis were used for direct evidence of presence of graphene domains in RHP reference sample.     

Effect of carbon black on electrical property of graphite nanoplatelets/epoxy resin composites

Epoxy/graphite nanoplatelets (GNPs)/carbon black (CB) composites were prepared by liquid mixing method. The morphologies and microstructures of the composites were examined by scanning electron microscope and X‐ray diffraction. The results indicated that CB can improve effectively the dispersion of GNPs and form excellent conductive network in the matrix. When the weight ratio of GNPs to CB was 9:1 (total filler content was 1 wt%), the conductivity of the composite was three orders of magnitude higher than that of composites with GNPs alone (1 wt%). The percolation threshold of GNPs_0.9CB_0.1/epoxy resin composites was 0.5 wt. %, which was lower than that of composites with GNPs alone (1 wt%). The mechanism for the effect of CB on electrical property of GNPs/epoxy resin composites was also investigated. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers.     

Optimization of wire electrical discharge machining parameters for cutting electrically conductive boron carbide

In this work, Pure boron carbide (B₄C) was consolidated using spark plasma sintering (SPS) at 2050 °C with a dwell of 10 min under 50 MPa uniaxial pressure in Argon atmosphere. The sintered specimen was >99% dense and offered characteristic Vickers hardness and fracture toughness of 31.4 GPa and 4.21 MPa-m^0.5, respectively, at 4.9 N indentation load. The specimen showed satisfactory wire electrical discharge machining (WEDM) performance because of its good electrical conductivity. The design of experiment (DOE) was arranged by L32 orthogonal array (OA) between the machining input parameters namely pulse on-time, pulse off-time, pulse peak current, dielectric fluid pressure and servo feed rate and the output responses like machining speed and surface roughness (R_a). Regression models were employed to establish the numerical correlation between the machining parameters and output responses. Experimental observations were utilized to formulate the first-order regression models to predict responses of WEDM. The optimized input parameters were 27 μs pulse on time, 48 μs pulse off time, 180 A pulse peak current, 7 kg/cm² water pressure and 2200 mm/min servo feed rate for the WEDM performance to produce an optimum machining speed and R_a.     

Synthesis and performance of TiB2–B4C composites by high pressure of TiC–B mixture

TiB₂–B₄C composites were in situ synthesized and consolidated by high pressure synthesis method from a mixture of TiC and B powders at the pressure and temperature of 5.0 GPa and 1500℃-1900℃. The phase composition, microstructure, density, hardness, thermal conductivity, and electrical resistivity of TiB₂–B₄C composites were analyzed. As the increase in the synthesis temperature, the products were TiB₂ and B₄C phases and that crystallinity improved. TiB₂–B₄C composites were dense without obvious pores. TiB₂–B₄C composites synthesized at 1800℃ obtained the optimized performance, including the relative density of 98.2%, the Vickers hardness of 31.7 ± 1.2 GPa with the load of 9.8 N, the thermal conductivity of 30.3 ± 0.7 W/(m K), and the electrical resistivity of 3.3 × 10⁻³ Ω cm, respectively. The grain size of the TiB₂–B₄C composites changed with the increase in synthesis temperature, leading to the changes in hardness, thermal conductivity, and electrical resistivity.     

Electrical conductivity maps in graphene nanoplatelet/silicon nitride composites using conducting scanning force microscopy

Graphene nanoplatelet (GNP)/silicon nitride (Si₃N₄) ceramic composites containing 12 and 15 wt.% of GNPs are prepared by mixing the nanoplatelets and the ceramic powders in a liquid medium followed by densification of the dried mixture by spark plasma sintering. The electrical conductivity of these composites is investigated at the nanoscale by conducting scanning force microscopy to understand the influence of the carbon phase content when above the percolation threshold. The establishment of a conducting network is revealed from the conduction measured at GNPs emerging at the surface of the composites. Current maps obtained for two orientations of the composites, parallel and perpendicular to the press sintering axis, show a preferential orientation of the nanoplatelets within the ceramic matrix. The effective current per conducting pixel, determined from the corresponding maps, is four times larger for the 15 wt.% GNP composite than for the 12 wt.% one. For the same composite (15 wt.%), differences in the effective current are measured for each of the two probing configurations. These results are interpreted in terms of unbalanced weight and nature of the resistors forming the percolated network.