Preparation of nickel-coated powders as precursors to reinforce MMCs

The preparation of nickel-coated ceramic particles as precursors for MMC fabrication was studied. Al₂O₃ and SiC powders of three different particle sizes were successfully coated with Ni using an electroless metal plating technique. Uniform and continuous nickel films were deposited on both, alumina and silicon carbide powders, with a final composition ranging from 1.6 to 1.9wt% phosphorus, 18–21wt% of metallic nickel and the balance is ceramic. XRD showed that the Ni-P deposit was predominantly amorphous. However, after heat treatment, the metallic deposits crystallize into Ni and Ni₃P phases, as confirmed by DSC analyses. Preliminary results showed that the use of Ni-coated powders enhances the wettability between the matrix and ceramic phase when processing particulate MMCs by infiltration techniques. The coating promoted easy metal flow through the preform, compared to the non-infiltration behavior of the uncoated counterpart samples.     

High-temperature oxidation of ceramic matrix composites dispersed with metallic particles

Oxidation behavior of ceramic matrix composites dispersed with metallic particles is discussed to establish materials design for high-temperature applications. Oxidation kinetics of ceramic matrix composites dispersed with metallic particles is understood from the viewpoint of the diffusion properties and defect chemistry of matrix oxides. High-temperature oxidation of Ni(p)/partially stabilized zirconia, Ni(p)/Al₂O₃ and Ni(p)/MgO was described as examples.     

A novel in-situ polymer derived nano ceramic MMC by friction stir processing

Friction stir processing (FSP) is a solid state technique used for material processing. Tool wear and the agglomeration of ceramic particles have been serious issues in FSP of metal matrix composites. In the present study, FSP has been employed to disperse the nanoscale particles of a polymer-derived silicon carbonitride (SiCN) ceramic phase into copper by an in-situ process. SiCN cross linked polymer particles were incorporated using multi-pass FSP into pure copper to form bulk particulate metal matrix composites. The polymer was then converted into ceramic through an in-situ pyrolysis process and dispersed by FSP. Multi-pass processing was carried out to remove porosity from the samples and also for the uniform dispersion of polymer derived ceramic particles. Microstructural observations were carried out using Field Emission Scanning Electron Microscopy (FE-SEM) and Transmission Electron Microscopy (TEM) of the composite. The results indicate a uniform distribution of ~ 100 nm size particles of the ceramic phase in the copper matrix after FSP. The nanocomposite exhibits a five fold increase in microhardness (260HV₁₀₀) which is attributed to the nano scale dispersion of ceramic particles. A mechanism has been proposed for the fracturing of PDC particles during multi-pass FSP.     

Electrocatalytic action of nano-SiO2 with electrodeposited nickel matrix

The present work focuses on the electrocatalytic effect of nano-SiO₂ on nickel electrodeposition and chemical interaction between nano-SiO₂ and nickel in composite coating. The electrochemical behavior from n-SiO₂/Ni composite brush plating system and quick nickel solution are investigated using cyclic voltammetry. The interaction between n-SiO₂ particles and matrix metal nickel is researched by X-ray photoelectron spectrometry. The results show that the n-SiO₂ take part in the electrode reaction during nickel electrocrystallization and can catalyze the nickel electrodeposition. The unsaturated bond of oxygen on n-SiO₂ particles surface can capture some of the absorbed nickel atoms and form nickel–oxygen chemical bond. It is proved that the chemical binding interaction exists in the interface between nanoparticles surface and matrix metal nickel.     

WC、ZrO2 、Cr2O3 和Al2O3 陶瓷颗粒/ 镍合金复合涂层微观组织结构的分形

采用等离子喷涂工艺, 制备了WC、ZrO₂ 、Cr₂O₃ 和Al₂O₃ 陶瓷颗粒/ 镍合金复合涂层。用X 射线衍射研究了陶瓷颗粒复合涂层相的分布; 用里氏硬度计测量陶瓷颗粒/ 镍合金复合涂层的硬度; 用CSS-1110 电子万能试验机研究陶瓷颗粒复合涂层的弯曲断裂性能。对涂层金相组织结构进行二值化处理, 利用Sandbox 法对陶瓷颗粒在金属基体中的分布进行研究, 得到了不同体积分数下陶瓷颗粒复合材料涂层的分维数。结果表明,陶瓷颗粒/ 镍合金复合涂层分维数随陶瓷颗粒含量的增加而增加, 与陶瓷颗粒种类无关; 陶瓷颗粒/ 镍合金复合涂层硬度和分维数随陶瓷颗粒直径减小而增加。随着分维数的增加, 复合涂层弯曲断裂角下降。      

Improving the fracture toughness of MgO–Al2O3–SiO2 glass/molybdenum composites by the microdispersion of flaky molybdenum particles

The flake-forming behaviour of powders of molybdenum, niobium, nickel, BS 316 S 12, Ni–17Cr–6Al–0.6Y, iron, titanium and Ti–6Al–4V, using a wet ball mill, was investigated. MgO–Al₂O₃–SiO₂ (MAS) glass composites reinforced with these flaked particles were fabricated, and improvements in flexural strength evaluated. The MAS glass composites reinforced with flaky metallic particles such as molybdenum, niobium, iron, nickel and Ni–17Cr–6Al–0.6Y, showed an improvement. The effect of molybdenum particle size on the flake-forming behaviour of molybdenum, flexural strength and fracture toughness of MAS glass/molybdenum composites, were investigated. The flake-forming behaviour shows a high degree of dependence on molybdenum particle size and, upto a size of 32 μm, becomes conspicuous with increasing particle size. At 32 μm, the aspect ratio reaches a value of 17 and, above 32 μm, flake forming saturates. Fracture toughness is closely related to flake-forming behaviour and the more marked the flake forming, the greater is the increase in fracture toughness. A composite of MAS glass with flaky molybdenum particles has a greater improvement effect on fracture toughness than composites with SiC whiskers, SiC platelets or ZrO₂ particles. This is closely linked to plastic deformation of the flaky metallic particles at the crack tip at the time of fracture. This revised version was published online in November 2006 with corrections to the Cover Date.     

The preparation of AI2O3/Ni composites by a powder coating technique

In the present study, nickel particles are coated onto the surface of alumina powder by an impregnation technique. The densification behaviour and the microstructural evolution of the nickel coated alumina powder during sintering are investigated. The strength and the toughness of the resulting Al₂O₃/Ni composites are determined. As the nickel content is less than 13 vol%, fully dense composites can be prepared by pressureless sintering. The matrix grain size decreases as nickel inclusions are added. The strength and the toughness of alumina can be increased by 23 and 42% by adding 5 and 8vol% nickel, respectively. The toughening effect is attributed to plastic deformation of ductile inclusions and crack deflection by the inclusions. The strengthening effect is attributed to microstructural refinement.     

Opportunities for new graphitic aluminium metal matrix composite

Abstract

Nickel coated graphite particles have been incorporated into aluminium with a second particulate phase to produce graphitic aluminium metal matrix composites (Gr A-Ni) with improved processing, wear, and scuffing resistance. Excellent wear behaviour is provided by a combination of solid lubrication by graphite as well as high temperature strengthening of the matrix alloy by nickel present as Al₃ Ni intermetallics. Applications being developed include cylinder liners, pistons, connecting rods, various types of brakes, air diffusers and bushings. Neutral buoyancy of two particles, one of which is lighter and the other heavier than the aluminium matrix alloy, makes this a readily sand and die castable material. The presence of graphite and Al₃Ni intermetallics reduces the amount of ceramic particulate required to achieve the desired wear properties, with resulting improved machinability. The composition of the material can be tailored to the application. All these factors influence the finished part cost.     

Prediction of fracture strength in Al2O3/SiCp ceramic matrix nanocomposites

Based primarily on a recent publication [S.M. Choi, H. Awaji, Sci. Tech. Adv. Mater. 6 (2005) 2–10.], where the dislocations around the nano-sized particles in the intra-granular type of ceramic matrix nanocomposites (CMNCs) were modeled, dislocation activities in Al₂O₃/SiC_p CMNCs were discussed in relation to the processing conditions. The dislocations around the nano-sized particles, caused by the thermal mismatch between the ceramic matrix and nano-sized particles, were assumed to hold out the effect of Orowan-like strengthening, although the conventional Owowan loops induced by the movement of dislocations were unlikely in the ceramic matrix at room temperature. A model involving the yield strength of metal matrix nanocomposites (MMNCs), where the Owowan strengthening effect was taken into consideration, was thus modified and extended to predict the fracture strength of the intra-granular type of CMNCs without and with annealing. On the basis of the characteristics of dislocations in the CMNCs, the load-bearing effect and Orowan-like strengthening were considered before annealing, while the load-bearing effect and enhanced dislocation density strengthening were taken into account after annealing. The model prediction was found to be in agreement with the experimental data of Al₂O₃/SiC_p nanocomposites reported in the literature.     

SiC matrix composites containing transition metal boride particulates internally synthesised by carbothermal reaction

SiC matrix composites reinforced with the various borides of the transition metals in group IV a-VI a, which were synthesized from the transition metal oxide, boron carbide and carbon mixed with SiC powder. Dense composites containing boride particulates of titanium, zirconium, niobium and chromium were prepared through reactive hot-pressing. The morphology of the internally synthesized boride particles reflected that of the starting oxide powders. SiC-NbB₂ composites with four-point flexural strength of 500 to 600 MPa and better oxidation resistance than SiC-TiB₂ were prepared even through pressureless sintering process. Pressureless-sintered and HIPed SiC-20 vol% NbB₂ exhibited the four-point flexural strength of 760 MPa at 20 °C and 820 MPa at 1400 °C.     

Effect of silica-coating on crystal structure and magnetic properties of metallic nickel particles

The development of a simple method that perfectly controls the oxidation and aggregation of metallic particles has been performed. In the present work, metallic nickel (Ni) particles were used as a control, and silica-coating of them was performed to control oxidation and aggregation of them. Metallic Ni particles with a particle size of 924.1 ± 315.7 nm were synthesized in water and exposed to air. Nickel(II) acetate tetrahydrate, hydrazine, and poly(sodium 4-styrenesulfonate) were used as the Ni source, reducing reagent, and stabilizer, respectively. Silica-coating of the metallic Ni particles was performed by adding tetraethylorthosilicate/(3-aminopropyl)triethoxysilane/ethanol solution to the metallic Ni particle colloid solution (Ni/SiO₂). The uncoated metallic Ni particles and metallic Ni in the Ni/SiO₂ particles began to be oxidized while annealing in air to form NiO at 400 and 500 °C, respectively; the oxidation of metallic Ni particles was controlled by the silica coating. The Ni/SiO₂ particles prepared and annealed at 100–300 °C showed soft magnetic behavior, and the saturation magnetization of g-Ni was almost comparable to that of bulk metallic Ni. In addition, the Ni/SiO₂ particles annealed even at 500 °C still had soft magnetic behavior, which also supported that the oxidation of metallic Ni particles was successfully controlled by the silica coating.     

Einfluss einer PVD‐Al‐Zwischenschicht auf die Eigenschaften eines thermisch gespritzten Wärmedämmschichtsystems nach Temperaturwechselbelastung

Thermal barrier coatings (TBC) generally consist of a metallic bond coat (BC) and a ceramic top coat (TC). Co–Ni–Cr–Al–Y metallic super alloys and Yttria stabilised zirconia (YSZ) have been widely used as bond coat and top coat for thermal barrier coatings systems, respectively. As a result of long‐term exposure of thermal barrier coatings systems to oxygen‐containing atmospheres at high temperatures, a diffusion of oxygen through the porous ceramic layer occurs and consequently an oxidation zone is formed in the interface between ceramic top coat and metallic bond coat. Alloying components of the BC layer create a so‐called thermally grown oxides layer (TGO). One included oxide type is α‐Al₂O₃. α‐Al₂O₃ lowers oxygen diffusion and thus slows down the oxidation process of the bond coat and consequently affects the service life of the coating system positively. The distribution of the alloying elements in the bond coat layer, however, generally causes the formation of mixed oxide phases. The different oxide phases have different growth rates, which cause local stresses, micro‐cracking and, finally, delamination and failure of the ceramic top coat layer. In the present study, a thin Al inter‐layer was deposited by DC‐Magnetron Sputtering on top of the Co–Ni–Cr–Al–Y metallic bond coat, followed by thermal spraying of yttria‐stabilised zirconia (YSZ) as a top coat layer. The deposited Al inter‐layer is meant to transform under operating conditions into a closed layer with high share of α‐Al₂O₃ that slows down the growth rate of the resulting thermally grown oxides layer. Surface morphology and microstructure characteristics as well as thermal cycling behaviour were investigated to study the effect of the intermediate Al layer on the oxidation of the bond coat compared to standard system. The system with Al inter‐layer shows a smaller thermally grown oxides layer thickness compared to standard system after thermal cycling under same conditions.     

Synthesis and characterization of functionally graded nickel‐nickel coated ZrO2 composite coating

Electroless‐nickel plated ZrO₂ (NCZ) particles have been used to produce a functionally graded nickel‐electroless‐nickel plated ZrO₂ composite coating. So, electroless‐nickel plated ZrO₂ particles concentration was continuously increased from 0 to an optimum value in the electroplating bath (Watt's bath). The substrate was ST37 steel and the thickness of the coating was approximately 50 μm. Also a uniformly distributed nickel‐electroless‐nickel plated ZrO₂ composite coating has been manufactured as comparison. The composite coatings were characterized by scanning electron microscopy and energy‐dispersive X‐ray spectroscopy. Structure and phase composition were identified by X‐ray diffraction analysis. Microhardness of the coatings was evaluated by employing a Vickers instrument. Three‐point bend test was carried out to compare the adhesion strength of the coatings. Dry sliding wear tests were performed using a pin‐on‐disk wear apparatus. The electrochemical behavior of the coatings was studied by electrochemical impedance spectroscopy. The microhardness measurements showed that, with increasing the co‐electrodeposited electroless‐nickel plated ZrO₂ particle content in the nickel matrix, the microhardness increases from interface towards the surface of the functionally graded composite coating. Bend, wear and electrochemical test results confirmed that the functionally graded composite coating has higher adhesion, wear resistance and corrosion resistance as compared with the uniformly distributed coating. This has been attributed to lower mechanical mismatch between coating and substrate in functionally graded composite coating with respect to the uniformly distributed one.     

Oxidizing heat treatment of nickel embedded in a barium titanate ceramic: kinetics and mechanisms of the metal oxidation

The use of nickel electrodes in combination with donor-doped BaTiO₃ for ceramic multilayer capacitors was investigated. Their use requires a reducing sintering atmosphere in order to maintain the metallic state. Afterwards such devices have to be exposed to a short oxidizing heat treatment in order to transform the semiconducting ceramic into the insulating state. The results show, that from the kinetics such a treatment would be possible with the diffusion in a newly formed NiO layer being the rate-controlling step at 1000° C. However, the multilayer geometry and the fact that the oxidation of nickel consumes far more oxygen than the transformation of the ceramic from the semiconducting into the insulating state, do not allow the use of nickel electrodes in combination with a donor-doped BaTiO₃ ceramic.     

High Temperature Behavior of Si3N4 and Yb2SiO5 Coated Carbon Fibers for Silicon‐Nitride CMC

For oxide‐free ceramic matrix composites (CMC), with Si₃N₄ matrix and carbon fiber reinforcement, for extreme high temperature applications, protective coatings of the C‐fibers are investigated. Two different coatings are compared: reactive CVD‐derived pure Si₃N₄ coatings to investigate C‐fiber‐matrix reactions and powder based Yb‐silicate coatings to reveal potential reactions with the Yb‐silicate additive serving as sintering aid for Si₃N₄. The reactivity toward carbon in nitrogen atmosphere is studied in the temperature interval from 20 °C up to 1700 °C. A new ceramic phase – an Yb‐carbido‐nitiridosilicate, Yb₂Si₄CN₆–is found as product of carbothermal reduction of the Yb‐silicate. The carbothermal reduction occurs also with other RE‐silicates, RE = Yb, Er, Y, Gd, and Sm while SiC is found as reaction product on carbon fibers coated with pure Si₃N₄. The oxidation resistance of the coated fibers in air was investigated in the temperature interval up to 1000 °C, and the apparent activation energy of oxidation was analyzed based on DTA‐EGA results. The oxidation kinetic reveals a significant increase of onset point of oxidation temperature by up to 150 K for Si₃N₄ coated short carbon fibers obtained from the reactive CVD coating process. Such fibers have a high application potential for carbon‐fiber reinforced Si₃N₄‐CMC. The role of Yb₂Si₄CN₆ as reinforcement for Si₃N₄‐CMC is discussed based on bond strength comparison of carbides (SiC), nitride silicates (SiAlON), and nitrides (Si₃N₄).     

Nickel and copper deposition on Al2O3 and SiC particulates by using the chemical vapour deposition–fluidized bed reactor technique

A chemical vapour deposition–fluidized bed reactor technique was developed to perform metal deposition on ceramic particulates. Experiments of nickel and copper deposition on Al₂O₃ and SiC particulates were conducted. Argon was used as the carrier gas to fluidize the ceramic particulates. The metal–H–Cl system was selected for the chemical vapour deposition. The volumetric ratios of the inlet gas were 3.5% HCl, 20.0% H₂, and 76.5% Ar. The deposition reactions were carried out at four different temperatures: 500, 600, 700 and 800 °C. Successful deposition of metallic nickel and copper on the ceramic particulates was observed. It was also noticed that the deposition rates varied with the types of substrates and deposited metals. This revised version was published online in November 2006 with corrections to the Cover Date.     

Mechanical properties of Nb2O5 and Ta2O5 prepared by different procedures

We have studied the mechanical properties of niobium pentoxide and tantalum pentoxide ceramics prepared by a conventional ceramic processing technique and by exposure to high-intensity light (HIL). The results demonstrate that, after HIL exposure in an optical furnace, the niobium pentoxide and tantalum pentoxide ceramics possess enhanced microhardness and improved mechanical properties (strength, fracture toughness, and brittle microstrength) owing to the formation of fractal micro- and nanostructures. With increasing exposure intensity, the strength of the Nb₂O₅ and Ta₂O₅ ceramics increases.     

Electro co-deposition of Ni–Al2O3 composite coatings

Nickel–Al₂O₃ composite coatings have been successfully deposited galvanostatically on to stainless steel substrates by electro co-deposition from a Watts bath containing between 50 and 150?g/l of sub-micron or nano- sized alumina particles applying current density of ?10, ?20 and ?32?mA?cm^?2. The alumina distribution in the composite films on the two sides of the substrate was remarkably different due to solution hydrodynamics and electric field effects. The effect of current density, particle concentration in the bath and particle size are studied systematically producing a comprehensive set of data for better understanding the effects of these variables on the amount of particles co-deposited. The amount of Al₂O₃ co-deposited in the films increases with the particle concentration in the bath and strongly depends on the current density and on particle size. The effect of the current density and of the alumina inclusions on the crystallinity of the Ni matrix and on the Ni crystallites grain size has also been studied. The inclusions of nano or sub-micron-Al₂O₃ particles are found to strongly influence the metallic nickel microstructure.     

Metal Immiscibility Route to Synthesis of Ultrathin Carbides,Borides, and Nitrides

Ultrathin ceramic coatings are of high interest as protective coatings from aviation to biomedical applications. Here, a generic approach of making scalable ultrathin transition metal‐carbide/boride/nitride using immiscibility of two metals is demonstrated. Ultrathin tantalum carbide, nitride, and boride are grown using chemical vapor deposition by heating a tantalum‐copper bilayer with corresponding precursor (C₂H₂, B powder, and NH₃). The ultrathin crystals are found on the copper surface (opposite of the metal–metal junction). A detailed microscopy analysis followed by density functional theory based calculation demonstrates the migration mechanism, where Ta atoms prefer to stay in clusters in the Cu matrix. These ultrathin materials have good interface attachment with Cu, improving the scratch resistance and oxidation resistance of Cu. This metal–metal immiscibility system can be extended to other metals to synthesize metal carbide, boride, and nitride coatings.     

Fabrication of AA6061/Al2O3 nano ceramic particle reinforced composite coating by using friction stir processing

Nano ceramic particle reinforced composite coatings were created by incorporating Al₂O₃ ceramic particles into the surface of AA6061-T6 alloy plate with multiple pass friction stir processing (FSP). Optical microscopy and Micro-Vickers hardness tests were employed to investigate the influence of axial force and the number of FSP pass on the distribution of the ceramic particles and the hardness of the generated nano ceramic particle reinforced composite coating. Results show that the composite coating is as deep as the length of the pin probe. No distinct interface was developed between the coating and the base metal. The composite region becomes greater as the axial force and the number of FSP pass increased. At the same time, the distribution of the ceramic particles became more homogeneous. Nano particles in the coating have no significant effect on the macro-hardness of AA6061-T6 aluminum alloy even in the composite zone due to the softening of matrix material resulted from overaging. Spindle torque of the tool increased with increasing axial force, while it became less variable and smaller in subsequent pass compared to that in the first pass.