射频热等离子体制备球形氧化铝粉末的数值模拟及实验研究

研究粉末颗粒在热等离子体(ICTP)中的行为可以为射频等离子体制备球形粉末工艺过程的优化提供参考。首先, 利用FLUENT软件对具有不同粒径分布的氧化铝粉末颗粒在射频热等离子体中的运动轨迹及加热历程进行了数值模拟; 然后, 根据模拟结果所确定的实验参数范围进行了射频热等离子体粉末球化实验, 并将实验测量与数值模拟的结果相结合, 研究了输入功率、送粉速率等参数的改变对具有不同粒径分布的氧化铝粉末球化效果的影响。研究结果表明: 粒径较小的氧化铝粉末颗粒在飞行过程中可以从等离子体内吸收更多的热量, 因此能够被充分加热至完全熔化; 增加系统输入功率、降低送粉速率均能提高单位质量的颗粒从等离子体中获得的能量, 从而在一定程度上提升氧化铝粉末的球化率。     

射频等离子体球化SiO2粉体的研究

采用射频等离子体球化颗粒形状不规则的二氧化硅粉体,研究了加料速率、颗粒大小等因素对球化率的影响.用光学显微镜观察球化前后颗粒的形貌;用流动仪测定球化后粉体的松装密度.结果显示,球化后的二氧化硅颗粒球形度高,细颗粒长大,并且随着球化率的增大粉体松装密度增加.初步查明加料速率、原料粒度等参数对球化率的影响.在适当的条件下可以得到球化率高、球形度好的粉体.     

热等离子法制取高致密球形钼粉工艺探讨

本文采用自行研制的等离子设备实现了钼粉的球化,研究同时研究了工艺参数对钼粉球化的影响。用电子扫描显微镜（SEM）观测球化钼粉的微观形貌,用霍耳流速仪和斯科特容量计分别检测球形钼粉的流速和松比。研究表明,等离子体处理后钼粉形状由不规则变为球形,钼粉流动性显著提高,松比增大,且当输人功率为25kWh、送粉量50g／min钼粉的球化最为理想。     

等离子合成与雾化制粉技术及其应用

等离子体做为一种极端参数技术在粉体材料的球化处理与合成制备方面的研究和应用日益引起人们的关注。本文概述了等离子技术的主要特点及应用领域,综述了国内外有关射频等离子体对不同金属粉末、陶瓷粉末的球化处理及纳米粉末的合成方面的研究成果;介绍了北京科技大学在射频等离子体粉体处理系统开发、制备球形钨粉和钛粉方面的研究成果,在此基础上对等离子体粉体球化处理技术的应用前景进行了展望。     

机械合金化法制备TiFe基储氢合金的研究

采用机械合金化法，以Ti、Fe粉为原料制备TiFe基储氢合金。详细考察了机械合金化法制备TiFe纳米储氢合金的制备工艺，分析了球磨过程中球磨气氛、球磨介质、转速、球料比以及球磨时间等因素对产物性能的影响；采用x射线衍射分析（XRD）、扫描电镜分析（SEM）及粒度分布等方法研究了合金体系的相结构、微观组织形貌和粒度等。     

原位自生TiCp/6061复合材料的组织、硬度及耐磨性能

采用接触反应法制备了原位自生Ti Cp/6061复合材料,利用XRD和SEM对复合材料进行物相分析及微观形貌观察,用6061铝合金基体材料作为对比,研究了增强粒子含量对复合材料硬度和摩擦磨损行为的影响。结果表明,采用接触反应法,以Ti粉、C粉和Al粉作为生成Ti C增强相的原材料,可直接在6061铝合金基体中原位生成Ti C颗粒,Ti C颗粒呈规则多边形,尺寸为0. 5～1μm。随着增强粒子含量的增加,原位自生Ti Cp/6061复合材料的硬度明显提高,T6热处理后5%(质量分数)的Ti Cp/6061复合材料的硬度为120. 5HBS,比基体6061铝合金提高了28. 1%。这是Ti C颗粒对6061基体材料的位错强化和细晶强化综合作用的结果。此外,随着增强粒子含量的提高,原位自生Ti Cp/6061复合材料的耐磨性也增强; T6热处理后,在100 N恒压作用下与GCR15材料对磨300 s,基体6061铝合金失重是5%(质量分数) Ti Cp/6061复合材料的2倍。其原因在于Ti C颗粒含量的提高减小了对磨材料与复合材料的有效接触面积,从而增强了原位自生Ti Cp/6061复合材料的耐磨性能。     

Visible photocatalytic activity of Ti-doped LaNi03 synthesized by solution combustion synthesis

采用溶液燃烧法制备了一系列不同Ti掺杂量的LaNiO3光催化剂，研究了Ti掺杂量对其相结构、形貌和光催化性能的影响。采用XRD、SEM、EDS及光致发光光谱（PL）等对其进行了表征和分析。结果表明：采用溶液燃烧法可获得单一钙钛矿相的LaNiO3，随着Ti掺杂量的增加，晶面间距逐渐增大；Ti掺杂量对颗粒的形貌大小影响较小，颗粒近似球形，粒径分布均匀，约为80nm。可见光催化实验结果表明，当Ti掺杂量为3．0％（质量分数）时，所得催化剂的催化效果最好，适量的Ti掺杂可显著降低光生载流子的复合几率。     

Zr对(Ag-Cu-Ti)-SiCp钎焊SiC陶瓷/钛合金连接层组织结构的影响

使用Ag-Cu-Ti合金粉,SiC粉和Zr粉组成的混合粉末钎料,真空无压钎焊再结晶SiC陶瓷与Ti合金,观察Zr加入前后接头连接层组织结构的变化,研究了Zr的作用．结果表明,Zr加入前,连接层主要由Ag、SiC、Cu—Ti、Ti3SiC2、和Ti-Si相组成．Zr加入后,连接层主要由SiC、Ti1-xC、Ti-Si、AgTi和AgCu4Zr相组成．Zr的加入提高了连接层中Ti的活度,使SiC颗粒表面反应层Ti3SiC2转变,生成了Ti1-zC和TiSi相;提高了Ti与SiC颗粒的反应速度,使SiC颗粒减少;促进Ti与Ag的反应,生成了AgTi．Zr的加入导致连接层流动性的改善、连接层与SiC陶瓷界面结合强度的提高和接头热应力的降低,适量Zr的加入使接头剪切强度明显提高（达23．6MPa）．     

高能球磨及热挤压对Al-Ti-B细化剂纳米TiB2颗粒分散性与细化性能的影响

为获得高晶粒细化性能的Al-Ti-B细化剂,本文利用高能球磨法在微米Ti粉上负载纳米TiB₂颗粒制备了Ti/TiB₂粉末细化剂,并采用热挤压工艺制备了杆状Al-Ti-B细化剂,对比分析了两种细化剂的晶粒细化性能及机理。研究表明:高能球磨可将纳米TiB₂颗粒均匀负载分散在微米Ti粉表面,使工业纯铝的平均晶粒尺寸细化至74.6 μm;热挤压则使细化剂致密化,微米Ti粉及纳米TiB₂颗粒在铝基体中分布更加均匀,可将工业纯铝的平均晶粒尺寸进一步细化至58.4 μm,获得最佳细化效果,并使细化剂的抗衰退性能提高。机理分析表明,随着细化剂中纳米TiB₂颗粒的分散性提高、团聚现象减缓,其在铝熔体中的沉降速度缓慢,对晶粒的形核促进作用、长大抑制作用更充分,是热挤压Al-Ti-B细化剂对工业纯铝有优异晶粒细化效果的关键。     

生物模板法制备具有特殊表面形貌的二氧化硅中空微球

利用油菜花粉作为生物模板,通过溶胶在花粉颗粒表面包裹,再经高温烧结去除花粉颗粒的方法制备了具有特殊表面形貌的二氧化硅中空微球. 并通过调节溶胶中醇盐与水的比例,实现了不同表面形貌的二氧化硅中空微球的制备. 利用差热（DSC）、热重（TG）、X射线能谱仪（EDS）、扫描电子显微镜（SEM）等对花粉颗粒和所制备的二氧化硅中空微球进行了表征,并对不同表面形貌的形成机理进行了探讨. 结果表明,花粉内壁在200℃时即可完全消除,从而形成中空结构,而外壁及其表面的网格状结构在较高温度仍能保持完好,从而保证该结构在微球表面的复制,而溶胶浓度则是形成微球表面不同形貌的决定因素,随着胶体粒子在花粉表面沉积量的不同,微球表面的微孔结构也将随之变化.     

Plasma spheroidization of iron powders in a non-transferred DC thermal plasma jet

In this paper, the results of plasma spheroidization of iron powders using a DC non-transferred plasma spray torch are presented. The morphology of the processed powders was characterized through scanning electron microscopy (SEM) and optical microscopy (OM). The percentages of spheroidized powders were calculated by the shape factors such as the Irregularity Parameter (IP) and Roundness (RN). A maximum of 83% of spheroidization can be achieved. The spheroidization results are compared with the theoretical estimation and they are found to be in good agreement. The phase composition of the spheroidized powder was analyzed by XRD. The effect of plasma jet temperature and plasma gas flow rate on spheroidization is discussed. At low plasma gas flow rates and at high plasma jet temperatures, the percentage of spheroidization is high.     

Spheroidization of tantalum powder by radio frequency inductively coupled plasma processing

In this work, we used radio frequency (RF) plasma spheroidization to transform irregularly shaped tantalum powders to spherical ones. After RF plasma treatment, the majority of particles were spheroidized with the presence of a small number of irregular particles. The mean particle size becomes finer and the particle size distribution narrower, as compared with the starting powder. A few non-spherical or even irregular tantalum powders still existed. Although argon gas was used in the plasma chamber, oxygen contamination still occurred. A thin layer of oxide film was found on the surface of particles, while the particle interiors were inferred free of oxygen. The powder characteristics had been significantly improved. After spheroidization treatment, the apparent density, tap density and powder flowability significantly increased from 7.03 g/cm³ to 8.9 g/cm³, 8.6 g/cm³ to 10.05 g/cm³, and 12.41 s/(50 g) to 7.96 s/(50 g), respectively, in comparison with that of raw powders. This study presents a feasible method for fabricating spherical tantalum powders, which may potentially broaden the application for metal additive manufacturing.     

Fabrication of fine-grained spherical tungsten powder by radio frequency (RF) inductively coupled plasma spheroidization combined with jet milling

Fine-grained spherical tungsten powder with particle size from 6 μm to 11 μm has been fabricated by a well-designed method with two simple steps. A pretreatment of tungsten powder was carried out in the first step. Complete dispersion, effective classification and favorable shape modification have been achieved by jet milling process. Accordingly, monodisperse tungsten powders with narrow particle size distribution were obtained. On the basis of the existing calculation and simulation results, plasma spheroidization parameters have been optimized. Thus, fine-grained spherical tungsten powder with narrow particle size distribution has been prepared by subsequent radio frequency (RF) inductively coupled plasma spheroidization. Furthermore, the presented method can be useful in fabricating spherical tungsten powder of different particle size with narrow particle size distribution as well as for process control in large-scale continuous production.     

Characterization of Virgin,Re-used,and Oxygen-reduced Copper Powders processed by the Plasma Spheroidization Process

Fabrication of parts with high mechanical properties heavily depend on the quality of powder deployed in the fabrication process. Copper powder in three different powder types were spheroidized using radio-frequency inductively coupled plasma (ICP) spheroidization process (TekSphero-15 system). The characterized powders include virgin powder as purchased from the powder manufacturer, powder used in electron beam powder bed fusion (EB-PBF) process, and reconditioned powder, which was used powder that underwent an oxygen-reduction treatment. The goal of spheroidizing these powder types was to evaluate the change in powder morphology, the possibility of enhancing the powder properties back to their as-received conditions, and assess oxygen reduction of the powder lots given their initial oxygen contents. Also, to investigate the impact of re-spheroidization on powder properties, the second round of spheroidization was performed on the already used-spheroidized powder. The impact of powder type on powder sphericity and particle size distribution was evaluated using the image analysis of scanning electron microscope (SEM) micrographs and laser diffraction, respectively. The spheroidized powder showed higher sphericity and more uniform particle size distribution overall. Depending on the powder collection bin, second round of spheroidization affected the powder sphericity differently. The possibility of deploying the plasma spheroidization process as an alternative oxygen-reduction technique was also investigated through tracking the powders’ oxygen content using inert gas fusion method before and after the spheroidization. The plasma spheroidized powder showed less oxygen content than the hydrogen-treated powder. The second round of spheroidization caused no change in oxygen content. The correlation between oxygen-reduction and created cracks was discussed and compared between plasma spheroidization and hydrogen-treatment. The plasma spheroidization process created a powder with higher sphericity, uniform particle size, and less oxygen content.     

Formation of highly oriented hydroxyapatite in hydroxyapatite/titanium composite coating by radio-frequency thermal plasma spraying

Highly oriented hydroxyapatite (HA) coatings with excellent adhesion were successfully obtained on titanium (Ti) and titanium alloy through a radio-frequency thermal plasma spraying method. The ratio of HA and Ti powders supplied into the plasma was precisely controlled by two microfeeders so as to change the composition from Ti-rich to HA-rich toward the upper layer of the formed coatings. The bond (tensile) strength of the HA/Ti composite coatings was ca. 40–50 MPa. XRD patterns showed that the topmost HA layer of the coatings had an apatite structure with (00l) preferred orientation. The degree of this orientation showed a tendency to increase with an increase in the substrate temperature during spraying.     

Influence of two-step ball-milling condition on electrical and mechanical properties of TiC-dispersion-strengthened Cu alloys

TiC-dispersion-strengthened Cu alloys were prepared by a two-step ball-milling (BM) process followed by sparks plasma sintering (SPS), heat treatment and hot rolling in sequence. The two-step BM process is composed of a pre-ball-milling (pre-BM) on both Ti and graphite powders as well as a subsequent homogenizing by BM together with Cu powder. Microstructure evolution analysis was performed to evaluate the effects of BM conditions on the electrical and mechanical properties of Cu-based alloys. The X-ray results revealed that titanium carbide (TiC) formed from Ti and C under high impact energy BM. Moreover, the formation of TiC during the SPS and heat treatment processes was found to more beneficial in enhancing the mechanical properties of alloy. The residual Ti in Cu matrix was found to be the predominant factor lowering the electrical conductivity of Cu–Ti–C alloys.     

Fabrication of spherical Ti-6Al-4V powder by RF plasma spheroidization combined with mechanical alloying and spray granulation

Spherical Ti-6Al-4V powder was produced by RF plasma spheroidization combined with mechanical alloying and spray granulation. Particle size distribution, morphology, specific surface area, apparent density, flowability, element distribution and content of alloy powders after each stage during the process were investigated. Results show that the obtained spheroidized Ti-6Al-4V alloy powder has dense structure, good sphericity and high spheroidization ratio (98%), moderate particle size (37.8 μm) with narrow distribution. It also has excellent flowability (33.2 s· (50 g)^-1) and apparent density (2.53 g·cm^?3). In addition, elements distribution in the spherical Ti-6Al-4V alloy powder is uniform and most of elements content of it is within the standard of Ti-6Al-4V alloy.     

Characterization and comparison between APS coatings prepared from ball milled and plasma processed nickel–aluminium powders

Plasma spraying has wide range of applications which include corrosion, thermal and abrasion resistance coatings. In the present work, nickel and aluminium powders were ball milled and the same were thermal plasma processed to produce spherical nickel alumindes particles. Both ball milled and plasma processed powders were spray deposited on stainless steel (SS 304) substrate using atmospheric plasma spray technique (APS). The experiments were carried out for different plasma input power levels, torch to base distances and coating thicknesses. Microstructure, micro hardness, adhesive strength, and porosity of the coatings are reported and discussed. Effect of plasma processing parameters and plasma spheroidization of powders on coating properties has been evaluated and reported. High plasma power, low torch to base distance lead to high temperature supplied to in-flight particles which correspond to high hardness, low porosity and high adhesion. Spherical morphology and formation of nickel aluminide intermetallic were achieved by plasma spheroidization. Coatings prepared from plasma processed powders enhance the coating properties positively.     

感应等离子体技术制备球形铸造碳化钨粉体及其性能表征

球形碳化钨增强金属基复合涂层具有高硬度、高韧性和优异的耐磨、耐蚀性等特点,可以对材料表面起到有效保护作用。传统铸造碳化钨粉体多呈不规则的片状或多角状,流动性差且硬度低,难以满足高性能涂层材料的要求。本文以多角状铸造碳化钨粉体为原料,采用感应等离子体技术制备球形碳化钨粉体,研究感应等离子体技术工艺参数对碳化钨粉体球化效果的影响规律。采用扫描电子显微镜、X射线衍射仪、霍尔流速计、激光粒度分析仪等对球化处理前后碳化钨粉体的形貌、物相、松装密度、粒度分布进行表征。结果表明:送粉率为110 g/min、载气流量为5.0 L/min时,采用感应等离子体技术可制备颗粒饱满、表面光滑、分散性良好,球化率高达99%以上,且球形度较好的球形碳化钨粉体。球化后碳化钨粉体无孔洞等缺陷,内部组织为典型的细针状WC和W₂C的共晶,组织结构均匀细密。球化后碳化钨粉体的硬度高达3 258HV,提高了408HV;球化后碳化钨粉体的松装密度由8.01 g/cm³提高到9.75 g/cm³,霍尔流速由10.30 s/50 g降低到6.80 s/50 g,粉体的流动性提高。