Methodology for dependence-based integrated constitutive modelling: An illustrative application to SiCp/Al composites

In industrial forming and machining process, the large plastic deformation of material takes place in wide loading ranges of strain-rate and forming temperature. A satisfactory modelling of quasi-static and dynamic material behaviors is of great importance for understanding physical process and processes optimization. A dependence-based integrated methodology, together with an improved weighted multi-objective parameter identification strategy is presented for the development of phenomenological constitutive model and the parameter identification using experimental data from quasi-static and dynamic tests with instantaneous strain rate variations and plastic strain-related temperature changes. The improved multi-objective parameter identification model is reformulated by introducing three weighting factors for valuing different measure errors and fit standard errors in individual objective function corresponding to each test, considering the sampling point number and active material parameter number under different loading conditions, and balancing optimization opportunity of quasi-static and dynamic sub-objective functions. The methodology is verified for feasibility through illustrative constitutive identification for SiC_p/Al composites. This may provide a methodology of constitutive modelling for predicting material behaviors in quasi-static and dynamic modes equally well.     

Ultrasonic vibration-assisted laser engineering net shaping of ZrO2-Al2O3 bulk parts: Effects on crack suppression,microstructure, and mechanical properties

Laser additive manufactured zirconia-alumina ceramic (ZrO₂-Al₂O₃) parts demonstrate severe problems resulting from cracking and inhomogeneous material dispersion. To reduce these problems, we propose a novel ultrasonic vibration-assisted laser engineered net shaping (LENS) process for fabrication of bulk ZrO₂-Al₂O₃ parts. Results showed that the initiation of cracks and the crack propagation were suppressed in the parts fabricated by LENS process with ultrasonic vibration. For the parts fabricated without ultrasonic vibration, the sizes of cracks decreased with the increase of laser power. Scanning electron microscope analyses proved that the introduction of ultrasonic vibration was beneficial for grain refinement and uniform material dispersion. Due to the suppressed cracking, refined grains, and homogenized material dispersion, the parts fabricated with ultrasonic vibration demonstrated better mechanical properties (including higher microhardness, higher wear resistance, and better compressive properties), compared with the parts fabricated without ultrasonic vibration.     

Catalytic graphene formation in coal tar pitch- derived carbon structure in the presence of SiO2 nanoparticles

A simple and effective way to manufacture graphene from a coal tar pitch (CTP) is demonstrated. Silica (SiO₂) nanoparticles were used to modify the CTP as carbon precursor. A silica nanofiller introduced into the CTP matrix underwent carboreduction during heat treatment to 2000 °C, resulting in the formation of silicon carbide. Surfaces of SiC grains were sites for graphene formation. The influence of SiO₂ on the structure and microstructure of CTP- based carbon matrix, after annealing up to 2800 °C, was studied. Carbon samples were analyzed using X- ray Diffraction (XRD), Transmission Electron Microscopy (TEM) and Raman Spectroscopy. Crystallite sizes (L_a, L_c) and interplanar distance (d₀₀₂) were determined. The presence of SiO₂ in CTP carbon precursor favored the crystallites’ growth in the ‘a′ crystallographic graphite direction, and inhibited their growth on the ‘c′ axis. The crystallites composing of graphene layers, were characterized by an elongated dimension in the ‘a′ axis direction. Above 2000 °C silicon carbide decomposed, followed by the sublimation of silicon from the carbon matrix.     

Copper-alumina nanocomposite coating on copper substrate through solution combustion

The main objective of the present research is to investigate the production of Cu-Al₂O₃ nanocomposite coating on a copper substrate using solution combustion synthesis. Solution combustion synthesis is mainly used to produce nanocomposite powders; however, in this study it is applied to produce nanocomposite coat. For this purpose, both copper and aluminum nitrates (Cu (NO₃)₂·3H₂O and Al (NO₃)₃·9H₂O) are used as oxidizers. Also, urea and graphite are respectively used as fuel to synthesize the Cu-Al₂O₃ nanocomposite and as inhibitor to prevent the oxidation of the synthesized copper. The microstructure and morphology of the nanocomposite coating, which includes 25 wt% alumina as the reinforcing phase, was studied using X-ray diffraction, scanning electron microscopy, and transmission electron microscopy at different fuel/oxidizer ratios ranging from 0.9 to 2. The temperature variation during the process was measured as a function of time using a precise thermocouple. Finally, micro-hardness and wear tests were conducted on the nanocomposite coating. The results verified the formation of Cu-Al₂O₃ nanocomposite coating. Time-temperature curve illustrated that the highest temperature was achieved at the fuel/oxidizer ratio of 1.25. The results of the microhardness and wear resistance test showed that these properties depend heavily on the fuel/oxidizer ratio, with the best condition attained at the ratio of 1.25.     

Synthesis and two-step sintering behavior of solution derived corundum abrasives with plate-like grains

Corundum abrasives with plate-like grains were fabricated by a two-step sintering technique using the solution-based process with the addition of the ternary compound additive Na₃AlF₆-CaO-SiO₂. The two-step sintering method showed obvious advantages over conventional sintering methods in promoting sample densification, suppressing grain growth, and homogenizing the microstructure of the corundum abrasives. The sample doped with 2.5?wt% Na₃AlF₆ and 4?wt% CaO + SiO₂ in the molar ratio of 1:1 possessed a relative density of 99.3%, average grain size of 0.54?µm, and single-particle compressive strength of 49?N. The introduction of seeds reduced the temperature of θ- to α-Al₂O₃ phase transformation. The relationship between the microstructure and the mechanical properties of the abrasives was also discussed.     

Influence of calcium concentration on formation of tetravalent chromium doped Y3Al5O12 ceramics

Yttrium Aluminium Garnet (YAG) ceramics doped with chromium were prepared by solid-state reactive sintering in a vacuum. The influence of the charge compensator Ca²⁺ concentration on microstructure, optical properties and efficacy of Cr³⁺ oxidation to Cr⁴⁺ under air annealing was investigated. A non-monotonic dependence of these features on the amount of CaO as an additive was found. The changes in ceramic transparency and microstructure were explained considering the interaction between CaO and Cr₂O₃ at the ceramic grain boundaries, which leads to a different pore evolution in distinct samples during sintering. The efficacy of the oxidation of Cr³⁺ to Cr⁴⁺ strongly depends on the concentration of Ca dissolved in the YAG. The calcium solubility decreases due to the higher oxygen partial pressure of the extra phases on the grain boundaries that decreases the amount of generated Cr⁴⁺ ions. Such phenomenon explains the lower concentration of Cr⁴⁺ ions in the sample with 0.8% of Ca against the one with 0.5%. The experiment shows that the ceramic with 0.5% of Ca has a better in-line transmission and a higher concentration of Cr⁴⁺ ions in comparison with samples with a different Ca concentration.     

A novel route for synthesis of alumina–chromium carbide composites from PTFE-activated Cr2O3/Al/C combustion

Fabrication of alumina-chromium carbide composites was investigated by PTFE-activated Cr₂O₃/Al/C combustion synthesis. PTFE was employed as not only a reaction promoter, but a carburizing agent. Three reaction systems were prepared with different contents of carbon for the synthesis of Cr₂₃C₆, Cr₇C₃, and Cr₃C₂. The amounts of PTFE were selected to ensure combustion synthesis in the SHS (self-propagating high-temperature synthesis) mode and to provide carbon in quantities of 15 and 25?mol% of the total carbon. Experimental results showed that the combustion wave velocity and temperature decreased with increasing carbon, but increased with PTFE. A correlation between combustion wave velocity and temperature contributed to determination of the activation energy E_a =?89.15?kJ/mol for the combustion reaction. The increase of PTFE also improved formation of chromium carbides. As a result, the Cr₂₃C₆– and Cr₇C₃–Al₂O₃ composites were produced with almost no impurities. Due to a loss of carbon in carbothermic reduction, the Cr₃C₂–Al₂O₃ composite was obtained with Cr₇C₃ as the secondary carbide. SEM micrographs and DES analyses indicated that spherical carbide grains with a size of 0.5–3.0 μm were synthesized.     

Application of grits waste as a renewable carbonate material in manufacturing wall tiles

This work focuses on the reuse of grits waste, from cellulose industry, as a raw material to replace traditional carbonate material in ceramic wall tiles. Wall tile formulations bearing up to 15?wt% of the grits waste were prepared for replacement of calcareous. The tile manufacturing route consisted of dry powder granulation, uniaxial pressing, and firing at temperatures ranging from 1100?°C to 1180?°C by using a fast-firing cycle. The wall tile specimens were tested to determine their physical and mechanical properties (linear shrinkage, water absorption, apparent porosity, apparent density, breaking strength, and flexural strength). The firing behavior, phase transformations, and microstructure were evaluated by dilatometry, XRD, and SEM. The results showed that the fired wall tile specimens are composed of anorthite and quartz, as major mineral phases, and mullite as a minor phase. It was found that the grits waste had a positive influence on the properties and microstructure of the wall tile specimens. The results also revealed that the grits waste from cellulose industry could be used as a total replacement of traditional calcareous material in wall tile formulations.     

An investigation on the microstructural and electrical properties of La0.85DxSr0.15–xGa0.8Mg0.2O2.825 (D = Ba and Ca) electrolytes in solid oxide fuel cells

La_0.85D_xSr_0.15–xGa_0.8Mg_0.2O_2.825 (D = Ba and Ca, x?=?0, 0.01, 0.03, 0.05, and 0.07) electrolytes were synthesized using a solid-state reaction method, calcined at 1400?°C for 5?h, and sintered at 1400?°C for 5?h. The microstructures, electrical properties, and cell performances of the electrolytes and fuel cells were analyzed by X-ray diffraction, scanning electron microscopy, impedance analysis, and electrochemical analysis. La_0.85Ba_xSr_0.15–xGa_0.8Mg_0.2O_2.825 (LBSGM) and La_0.85Ca_xSr_0.15–xGa_0.8Mg_0.2O_2.825 (LCSGM) exhibit a dense structure and a cubic perovskite phase. Further, they contain small amounts of a secondary phase. The lattice constants of LBSGM and LCSGM are 0.3913–0.3914?nm and 0.3906–0.3909?nm, respectively. The average grain size of the sample increases with increasing Ba²⁺ or Ca²⁺ content. The conductivity of LCSGM (0.197–0.174?S/cm) is usually higher than that of LBSGM (0.181–0.162?S/cm) at 800?°C. The cells with La_0.85Sr_0.15Ga_0.8Mg_0.2O_2.825 and La_0.85Ca_0.03Sr_0.12Ga_0.8Mg_0.2O_2.825 electrolytes exhibit high open-circuit voltages and maximum power densities of 0.96?V and 542?mW/cm² and 0.94?V and 567?mW/cm², respectively, at 800?°C.     

A modified B2O3 containing Li2O-Al2O3-SiO2 glass with ZrO2 as nucleating agent - Crystallization and microstructure studied by XRD and (S)TEM-EDX

Glass-ceramics based on lithium-alumo-silicate glasses are commercially important for a wide range of applications, due to their special properties, like a vanishing thermal expansion. In order to tailor these properties, the composition of the glass and the temperature/time schedule are crucial factors. For the industrial production of most lithium-alumo-silicate glasses, high melting temperatures are required due to the high viscosities of the respective melt compositions. In this study, a simplified lithium-alumo-silicate glass composition with ZrO₂ as nucleating agent, on the basis of the commercially available Robax^® composition, is studied. Adding boron oxide leads to lower viscosities of the glass melt and notably lower melting temperatures may be supplied. The resulting glass is investigated using X-ray diffraction and transmission electron microscopy. During the crystallization process, phases such as ZrO₂ and β-quartz types are formed. The microstructure of the glass ceramics is notably coarser than that of glass-ceramics which are obtained from lithium-alumo-silicate glasses of standard compositions. EDX-analyses indicate a considerable enrichment of chemical elements in comparatively small areas of the microstructure. Especially boron oxide is found to be enriched in the residual glass of the investigated glass-ceramics.