Design and development of ceramic-based composites with tailored properties for cutting tool inserts

A successful approach to the development of tailored cutting tool materials requires the development of innovative concepts at each step of manufacturing, from the material design, synthesis of composite powders, to their processing and sintering. In this paper, a computational design approach is applied in the development of reinforced ceramic-based cutting tool inserts with tailored structural and thermal properties. Several potential filler materials are considered at the material design stage for the improvement of structural and thermal properties of a selected matrix material. Properties, such as an improved thermal conductivity and reduced coefficient of thermal expansion are essential for an effective cutting tool insert to absorb thermal shock at varying temperatures. In addition, structural properties such as elastic modulus have to be maintained within a moderate range. A mean-field homogenization theory and effective medium approximation using an in-house code are applied for predicting potential optimum structural and thermal properties for the required application. This is done by considering the effect of inclusions as a function of volume fraction and particle size in the ceramic base matrix. Single inclusion composites such as alumina-silicon (Al₂O₃-SiC) and alumina-cubic boron nitride (Al₂O₃-cBN) as well as hybrid composite such as alumina-silicon-cubic boron nitride (Al₂O₃-SiC-cBN) are developed using the Spark Plasma Sintering (SPS) process in line with the designed range of filler size and volume fraction to validate the computational results. It is found that the computational material design approach is precise enough in predicting the target properties of a designed hybrid composite material for cutting tool inserts.     

Nickel–alumina graded coatings obtained by dipping and EPD on nickel substrates

Nickel substrates have been coated by Ni/Al₂O₃ composite films by a dipping process using aqueous suspensions that contain a temporary binder. Two-layer and three-layer graded coatings have been produced, consisting of pure Ni powder and Ni/Al₂O₃ composites with Al₂O₃ contents of 15 and 30 vol.% as intermediate layers to release sintering and thermal stresses. The laminates were further coated with a ceramic layer of Al₂O₃/ZrO₂ that was deposited by electrophoretic deposition using a non-aqueous suspension. A continuous, thin Al₂O₃ layer surrounding Ni grains developed at the intermediate composite layer of Ni/Al₂O₃ allows the ceramic coating to maintain strongly adhered to the nickel substrate by means of a porous substrate/coating interface.     

Composite Ni/Al2O3 coatings and their corrosion resistance

Composite coatings Ni/Al₂O₃ were electrochemically deposited from a Watts bath. Al₂O₃ powder with particle diameter below 1 μm was codeposited with the metal. The obtained Ni/Al₂O₃ coatings contained 5-6% by weight of corundum. The structure of the coatings was examined by scanning electron microscopy (SEM). It has been found that the codeposition of Al₂O₃ particles with nickel disturbs the nickel coating's regular surface structure, increasing its microcrystallinity and surface roughness. DC and AC electrochemical tests were carried out on such coatings in a 0.5 M solution of Na₂SO₄ in order to evaluate their corrosion resistance. The potentiodynamic tests showed that the corrosion resistance of composite coating Ni/Al₂O₃ is better than that of the standard nickel coating. After 14 days of exposure the nickel coating corrodes three times faster than the Ni/Al₂O₃ coating. The electrochemical behaviour of the coatings in the corrosive solution was investigated by electrochemical impedance spectroscopy (EIS). An equivalent circuit diagram consisting of two RC electric circuits: one for electrode, nickel corrosion processes and the other for processes causing coating surface blockage, were adopted for the analysis of the impedance spectra. The changes in the charge transfer resistance determined from the impedance measurements are comparable with the changes in corrosion resistance determined from potentiodynamic measurements.     

Hydrogen Production from Partial Oxidation and Steam Reforming of N‐octane Over Alumina‐supported Ni and Ni‐Pd Catalysts

Hydrogen production by partial oxidation and steam reforming (POSR) of n‐octane was investigated over alumina‐supported Ni and Ni‐Pd catalysts. It showed that Ni‐Pd/Al₂O₃ had higher activity and hydrogen selectivity than the nickel catalyst under the experimental conditions, which indicated Ni‐Pd/Al₂O₃ could be an effective catalyst for the production of hydrogen from hydrocarbons.     

Physical properties and enzymatic hydrolysis of poly(L‐lactide)–TiO2 composites

Amorphous poly(L ‐lactide) (PLLA) composite films with titanium dioxide (TiO₂) particles were prepared by solution‐casting using methylene chloride as a solvent, followed by quenching from the melt. The effects of surface treatment, volume fraction, size, and crystalline type of the TiO₂ particles on the mechanical properties and enzymatic hydrolysis of the composite films were investigated. The tensile strength of the PLLA composite films containing TiO₂ particles except for anatase‐type ones with a mean particle size of 0.3–0.5 μm was lowered and the Young's modulus became higher with increasing the content of TiO₂ particles. The tensile strength of the composite films containing anatase‐type TiO₂ with a mean particle size of 0.3–0.5 μm at contents of 20 wt % or less was almost the same as that of the pure PLLA film. The enzymatic hydrolysis of PLLA matrix was accelerated by the addition of the hydrophilic anatase‐type TiO₂ particles (nontreated or Al₂O₃ treated) with a mean particle size of 0.3–0.5 μm at relatively high contents such as 20 wt %. On the other hand, the enzymatic hydrolysis of PLLA matrix was inhibited by composite formation with the hydrophobic rutile‐type TiO₂ particles (Al₂O₃‐stearic acid treated, or ZrO₂‐Al₂O₃‐stearic acid treated). These results suggest that the mechanical properties and enzymatic hydrolyzability of the PLLA can be controlled by the kind and amount of the added TiO₂ particles. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 96: 190–199, 2005     

Research on the preparation of Ni/Al2O3 powder by fluidized crystallization granulation–hydrogen reduction

This paper proposes a new process route for the preparation of Ni/Al₂O₃ composite powder through fluidized crystallization granulation–hydrogen reduction and investigates the effects of process feasibility, nickel concentration, nucleation method, and hydrogen reduction on Ni/Al₂O₃-coated powder. The decrease in nickel concentration, heterogeneous nucleation, and natural air-drying properties of precursor particles was beneficial to the formation of a complete and uniform cladding layer, and the increase in hydraulic retention time could improve the thickness of the cladding layer. The optimum process involves a nickel concentration of 50 mg/L; hydraulic residence time of 75 h to ensure heterogeneous nucleation; two-step hydrogen reduction of precursor particles to obtain a complete and uniform Ni/Al₂O₃ cladding layer; and a powder surface nickel content of 59.5%.     

Simultaneously enhanced mechanical properties and thermal properties of ultrahigh‐molecular‐weight polyethylene with polydopamine‐coated α‐alumina platelets

Polydopamine (PDA) was employed to modify micrometric Al₂O₃ platelets to improve the interfacial compatibility between α‐Al₂O₃ powder and ultrahigh‐molecular‐weight polyethylene (UHMWPE). The structure of PDA‐coated Al₂O₃ and UHMWPE composites was investigated via Fourier transform infrared spectroscopy, scanning electron microscopy and X‐ray photoelectron spectroscopy. The thermal stability and mechanical performance of the samples were also evaluated. It is clear that UHMWPE/PDA‐Al₂O₃ composites exhibit better mechanical properties, higher thermal stability and higher thermal conductivity than UHMWPE/Al₂O₃ composites, owing to the good dispersion of Al₂O₃ powder in the UHMWPE matrix and the strong interfacial force between the macromolecules and the inorganic filler caused by the presence of PDA. The tensile strength and the tensile elongation at break of UHMWPE/PDA‐Al₂O₃ composite with 1 wt% PDA‐Al₂O₃ are 62.508 MPa and 462%, which are 1.96 and 1.98 times higher than those of pure UHMWPE, respectively. The thermal conductivity of UHMWPE/PDA‐Al₂O₃ composite increases from 0.38 to 0.52 W m^?1 K^?1 with an increase in the dosage of PDA‐Al₂O₃ to 20 wt%. The results show that the prepared PDA‐coated Al₂O₃ powder can simultaneously enhance the mechanical properties and thermal conductivity of UHMWPE. © 2018 Society of Chemical Industry     

Development and performance analysis of novel in situ Cu–Ni/Al2O3 nanocomposites

Cu–Ni/Al₂O₃ nanocomposite powders were manufactured using an in situ chemical reaction technique. This technique provides improved wettability and adhesion between the matrix and reinforcement phases. Aluminum nitrate, copper nitrate and nickel nitrate were used as start materials for the production of the composites. The powders were sintered in a hydrogen environment at 900 °C for 2 h after being cold pressed at 700 MPa. To determine the effect of Al₂O₃ on electrical and thermal conductivities and thermal expansion behaviors, the Cu–Ni matrix was supplemented with 3, 5, and 8 wt% Al₂O₃. The findings revealed that Al₂O₃ nanoparticles (20 nm) were dispersed uniformly throughout the copper-nickel matrix. Microhardness was improved from 53.3 HV for Cu–Ni matrix to 92.7 HV for Cu–Ni/8%Al₂O₃ nanocomposites. The electrical and thermal conductivities and thermal expansion coefficient were reduced as the amount of Al₂O₃ in the Cu–Ni matrix increased. The electrical conductivity was reduced by 38.7% by addition 5% Al₂O₃ nanoparticles to Cu–Ni matrix. The high interfacial bonding between Cu–Ni and Al₂O₃ nanoparticles was the main reason of the hardness improvement and maintaining relatively good electrical and thermal properties.     

Effect of Catalyst Supports on Water‐Gas Shift Reaction at Ultrahigh Temperatures Using Syngas

Monometallic and bimetallic catalysts (Pt, Ni, and Pt‐Ni) with single support (Al₂O₃, TiO₂) and composite support (CeO₂/Al₂O₃, CeO₂/TiO₂) were prepared and tested for water‐gas shift reaction in a tubular quartz reactor. Syngas and steam with different steam‐to‐carbon ratios served as feedstock. The operating pressure was fixed while the reaction temperature was varied. The measured results indicated that the monometallic Ni/Al₂O₃ catalyst exhibits the lowest CO conversion and H₂ yield as compared with other catalysts. About the same CO conversion can be obtained from Pt and Pt‐Ni catalysts with single or composite support. However, higher H₂ yield can be achieved from the TiO₂‐supported catalyst compared with those supported by Al₂O₃. The experimental data also indicated that good thermal stability can be reached for the Pt‐based catalysts studied.     

HDPE‐Fly Ash/Nano Fly Ash Composites

Fly ash (FA) based polymer composites are assuming increasing importance because of its potentiality, fine particle size and plenty availability of FA. FA is mainly a mixture of inorganic metal oxides such as SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, Na₂O, TiO₂, and so forth. This article highlights the results of the various modifications onto the HDPE‐FA/nano structured FA (NFA) composites. When FA and NFA are melt blended with HDPE it gives rise to improved flexural properties only. Further modifications, that is, Maleic anhydride (MA) grafting of the matrix, electron beam irradiation of the composite and irradiation of the FA/NFA studied separately to find their impact on the detail properties of the composite. Of the three modifications implemented the electron beam irradiation of HDPE‐FA/NFA composite yielded excellent physico‐mechanical, thermal and dynamic mechanical properties. Fracture surface analysis of the HDPE, unmodified and modified FA/NFA composites studied employing SEM correlated well with the physico‐mechanical properties. The results prove that FA is valuable reinforcing filler for HDPE and its size reduction to nano level is a more effective criterion for its future use. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 4558–4567, 2013     

Development of a ceramic-based composite for direct bonded copper substrate

In the present paper, a computational approach is presented to design alumina-based composite with tailored properties that could replace commercial alumina used in Direct Bonded Copper (DBC) substrates for applications in power electronic modules. A mean-field homogenization and effective medium approximation (EMA) using an in-house code is used for predicting potential optimum thermal and structural properties for DBC substrates by considering the effect of filler type, volume, and size in the alumina matrix. The primary goal for designing such alumina-based composites is to have enhanced thermal conductivity for effective heat dissipation and spreading capabilities together with a coefficient of thermal expansion (CTE) value that is close to the silicon chips in electronic circuits in order to avoid interface layers. At the same time, other functional properties like elastic modulus and electrical conductivity have to be maintained. Our strategy incorporates thermal and structural properties of composites as a constraint on the design process. Among various metallic and carbon-based fillers, chromium, silicon carbide and diamond fillers were found suitable candidates that could enhance the thermal and structural performance of the alumina-based substrates. As a validation, we developed alumina-silicon carbide (Al₂O₃-SiC) composites in line with the designed range of filler size and volume fraction using Spark Plasma Sintering (SPS) process. Thermal and structural properties including thermal conductivity, CTE, and elastic modulus are measured to complement the computational design. It is found that the developed computational design tool is accurate enough in predicting the desired properties of composite materials for DBC substrate applications.     

Thermophysical behavior of thermal sprayed yttria stabilized zirconia based composite coatings

The effective thermal conductivity of a composite coating depends on intrinsic thermal conductivity of the constituent phases, its characteristics (size, shape) and volume fraction of porosities. The present study concerns studying the effect of CoNiCrAlY and Al₂O₃ content on the coefficient of thermal expansion and thermal conductivity of the YSZ (YSZ-CoNiCrAlY and YSZ-Al₂O₃) based composite coatings developed by thermal spray deposition technique. The coefficient of thermal expansion and thermal conductivity of the composite coatings were measured by push rod dilatometer and laser flash techniques, respectively, from room temperature to 1000 °C. Variation in density, porosity, coefficient of thermal expansion, and thermal conductivity was observed in the composite coatings with the addition of different volume fraction of CoNiCrAlY and Al₂O₃ powders in YSZ-CoNiCrAlY and YSZ-Al₂O₃ composites, respectively. Comparison between the theoretical and experimental thermal conductivities showed a mismatch varying from 4% to 58% for YSZ-CoNiCrAlY composite coatings and from 58% to 80% for YSZ-Al₂O₃ composite coatings. Model based analyses were used to understand the mechanism of thermal conductivity reduction in the composite coatings. It was concluded that the morphology of porosities varied with composition.     

Thermal conductivities of YSZ/Al2O3 composites

The thermal conductivities/diffusivities of YSZ/Al₂O₃ composites have been investigated by a laser flash technique. The thermal conductivity of the composite increases with an increase in the Al₂O₃ volume fraction, and it can be fitted well to the Maxwell theoretical model. The consistency of the thermal conductivities of the composites with the predicted values indicates the absence of obvious interfacial thermal resistances in the composites. The negligible thermal resistance effect from the YSZ and Al₂O₃ grain boundaries is due to the much lower phonon mean free path compared with the grain size in the composite. The low Kapitza resistance of the YSZ/Al₂O₃ interface is discussed in terms of the “clean” and coherent nature of the YSZ/Al₂O₃ interface, together with the small difference between the elastic properties of YSZ and Al₂O₃.     

Separation of bovine serum albumin (BSA) using γ‐Al2O3–clay composite ultrafiltration membrane

BACKGROUND: Ceramic membranes have received more attention than polymeric membranes for the separation and purification of bio‐products owing to their superior chemical, mechanical and thermal properties. Commercially available ceramic membranes are too expensive. This could be overcome by fabricating membranes using low‐cost raw materials. The aim of this work is to fabricate a low‐cost γ‐Al₂O₃–clay composite membrane and evaluate its potential for the separation of bovine serum albumin (BSA) as a function of pH, feed concentration and applied pressure. To achieve this, the membrane support is prepared using low‐cost clay mixtures instead of very expensive alumina, zirconia and titania materials. The cost of the membrane can be further reduced by preparing a γ‐alumina surface layer on the clay support using boehmite sol synthesized from inexpensive aluminium chloride instead of expensive aluminium alkoxide using a dip‐coating technique. RESULTS: The pore size distribution of the γ‐Al₂O₃‐clay composite membrane varied from 5.4–13.6 nm. The membrane was prepared using stable boehmite sol of narrow particle size distribution and mean particle size 30.9 nm. Scanning electron microscopy confirmed that the surface of the γ‐Al₂O₃–clay composite membrane is defect‐free. The pure water permeability of the support and the composite membrane were found to be 4.838 × 10^?6 and 2.357 × 10^?7 m³ m^?2 s^?1 kPa^?1, respectively. The maximum rejection of BSA protein was found to be 95%. It was observed that the separation performance of the membrane in terms of flux and rejection strongly depends on the electrostatic interaction between the protein and charged membrane. CONCLUSION: The successively prepared γ‐Al₂O₃‐clay composite membrane proved to possess good potential for the separation of BSA with high yield and could be employed as a low cost alternate to expensive ceramic membranes. Copyright © 2009 Society of Chemical Industry     

Oxidation resistance of Ni-toughened Al2O3

Adding nickel inclusions into alumina can enhance its strength and toughness. However, the oxidation resistance of alumina is degraded due to the presence of metallic nickel. In the present study, the oxidation kinetics of Ni-toughened Al₂O₃ in the temperature region from 1000 to 1300 °C are investigated. In the Al₂O₃/Ni composites, the Ni inclusions are isolated to each other within the Al₂O₃ matrix as the Ni content is less than 15 vol.%. The oxidation of the composites is mainly a diffusional process, nickel ions diffuse out and oxygen ions diffuse in. A dense NiAl₂O₄ spinel is formed on the surface of the composite after oxidation. The oxidation rate constants of the alumina incorporated with isolated Ni inclusions are in a comparable range with those of hot-pressed silicon nitride.     

Effect of Al2O3 particle size on the microstructure,phase transformation and mechanical properties of hot pressed Al2O3-CA6-ZrO2/Ni multi-phase composites

Al₂O₃-CA6-ZrO₂/Ni multi-phase composites were fabricated by vacuum hot pressing sintering at 1650 °C under the pressure of 30 MPa for 30 min. The microstructural evolution rule of the composites was investigated as a function of Al₂O₃ particle size. Upon increasing the Al₂O₃ particle size to 30 μm, the generated CA6 underwent a transformation from unfixed type to a plate-like pattern and to a combined CA6-Al₂O₃ matrix, whereas the fracture mode of m-ZrO₂ changed from an intergranular fracture to an intergranular and transgranular mixed type due to the improved interface binding energy. Additionally, satisfactory mechanical properties of the composites were achieved when the Al₂O₃ particle size was 30 μm. Under the synergistic effect of different strengthening and reinforcing phases, the inhomogeneous distribution caused by poor wettability between Al₂O₃ and Ni was effectively solved by the distributions of “intercrystalline type” and “intracrystalline type” for the Ni phase. The mechanisms of the microstructural evolution, phase transformation and improved mechanical properties are discussed in detail.     

Effect of mixed size particles reinforcing on the thermal and dynamic mechanical properties of Al2O3/PPS composites

Thermal and dynamic mechanical properties of polyphenylene sulfide (PPS) composites that were reinforced with different sized alumina (Al₂O₃) particles were studied. These composites were manufactured with two different sizes of Al₂O₃ particles 1 and 63 µm, using microcompounding and injection molding. Monosized Al₂O₃ particles reinforced up to 25 wt% loading content and mixed size Al₂O₃ particles reinforced at 15 wt% loading content as following particle weight proportions: 75% × 63 μm + 25% × 1 μm, 50% × 63 μm + 50% × 1 μm, 25% × 63 μm + 75% × 1 μm. Particle distribution investigations were performed by microcomputerized tomography (micro‐CT). Thermal properties were analyzed by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) methods and also dynamic mechanical properties were investigated by dynamic mechanical thermal analysis (DMTA) method. The results showed that mixed size Al₂O₃ particle reinforced composites showed a great enhancement in dynamic mechanical properties without significant change in thermal properties. It was concluded that mixed size particles showed a great synergy to give better results compared with monosized particle reinforced composites. POLYM. COMPOS., 37:3219–3227, 2016. © 2015 Society of Plastics Engineers     

Tribological behavior of micrometer‐ and nanometer‐Al2O3‐particle‐filled poly(phthalazine ether sulfone ketone) copolymer composites used as frictional materials

Micrometer‐ and nanometer‐Al₂O₃‐particle‐filled poly(phthalazine ether sulfone ketone) (PPESK) composites with filler volume fractions ranging from 1 to 12.5 vol % were prepared by hot compression molding. We evaluated the tribological behaviors of the PPESK composites with the block‐on‐ring test rig by sliding PPESK‐based composite blocks against a mild carbon steel ring under dry‐friction conditions. The effects of different temperatures on the wear rate of the PPESK composites were also investigated with a ball‐on‐disc test rig. The wear debris and the worn surfaces of the PPESK composites were investigated with scanning electron microscopy, and the structures of the PPESK composites were analyzed with IR spectra. The lowest wear rate, 7.31 × 10^?6 mm³ N^?1 m^?1, was obtained for the composite filled with 1 vol %‐nanometer Al₂O₃ particles. The composite with nanometer particles exhibited a higher friction coefficient (0.58–0.64) than unfilled PPESK (0.55). The wear rate of 1 vol %‐nanometer‐Al₂O₃‐particle‐filled PPESK was stable and was lower than that of unfilled PPESK from the ambient temperature to 270°C. We anticipate that 1 vol %‐nanometer‐Al₂O₃‐particle‐filled PPESK can be used as a good frictional material. We also found that micrometer‐Al₂O₃‐particle‐filled PPESK had a lower friction coefficient at a filler volume fraction below 5%. The filling of micrometer Al₂O₃ particles greatly increased the wear resistance of PPESK under filler volume fractions from 1 to 12.5%. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 993–1001, 2005     

The preparation of core–shell Al2O3/Ni composite powders by electroless plating

Core–shell nanostructured Ni-coated Al₂O₃ composite powders were synthesised by using the electroless plating method. The influence of the chemical components and powder concentration in the Ni coating was investigated by scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction techniques. The results show that the concentration of the plating components plays an important role in the formation of core–shell Al₂O₃/Ni composite powders. The nickel content in the composite powders could be effectively controlled by adjusting the nickel chloride content and the concentration of NaH₂PO₂·H₂O in the plating solution. The nanostructure of the crystalline Ni coatings was observed to be very attractive for achieving good bonding between ceramic particles and matrices for composite production.     

Preparation and characterization of Polyimide/Al2O3 nanocomposite film with good corona resistance

Polyimide/Al2O3 (PI/Al2O3) nanocomposite films based on pyromellitic dianhydride and 4,4′‐oxydianiline were fabricated by adding different proportions of nano‐Al₂O₃ inorganic particles via in situ polymerization. Microstructural analysis by scanning electron microscope (SEM) showed that the inorganic particles were homogenously dispersed in the PI matrix when mixed with appropriate amount of nano‐Al₂O₃. Fourier transform infrared spectroscopy and X‐ray diffraction analysis were also used to investigate the effect of nano‐Al₂O₃ on the polymerization process. The obtained composite films and pure film were characterized by thermogravimetry analysis, and the experimental results indicated that when comparing with pure film, the nanocomposite films displayed a better thermal stability than the pure one. Moreover, results also showed that the thermal stability of composite films steadily improved with increased content of nano‐Al₂O₃ particle. The electrical property test demonstrated that the composite films performed improving electrical breakdown strength and corona resistance. The microstructure changes of pure film and PI/Al₂O₃ nanocomposite films during corona aging have been analyzed by SEM. POLYM. COMPOS., 37:763–770, 2016. © 2014 Society of Plastics Engineers