Kinetic Spraying Deposition of Reactive-Enhanced Al-Ni Composite for Shaped Charge Liner Applications

Liners used in shaped charges (SC) must possess good penetration ability and explosive power. Producing the reactive layer (i.e., the Al-Ni composite) on a well-penetrating liner (i.e., Cu) via spray coating is a novel method; the exothermic reaction of this reactive layer can be enhanced by controlling the structure of the feedstock material. However, preceding studies have been unable to completely succeed in achieving this goal. There is still an opportunity to improve the performance of reactive layers in SC liner applications. In order to address this problem, a reactive Al-Ni composite powder was produced via arrested reactive milling (ARM) and deposited by a kinetic spray process. Afterward, the deposition state and self-propagating high-temperature synthesis (SHS) reaction behavior of the ARMed Al-Ni deposit were investigated. The deposition state was degraded by the ARM process due to the remaining solid lubricant and the strain-hardening effect, but the practically estimated bond strength was not poor (~40 MPa). No SHS reactions were induced by the ARM and kinetic spray process, which resulted in the quantitative maximization of the exothermic reaction. It is noteworthy that the initiation temperature of the SHS reaction was highly advanced (~300 °C) relative to preceding studies (~500 °C); this change is due to the additional mechanical activation initiated by the kinetic spray deposition.     

Co-continuous composite materials for friction and braking applications

Reactive infiltration of precursor ceramics (e.g., the formation of an alumina-aluminum composite by reaction of silica in liquid aluminum) is a low-cost and versatile method of creating materials with interpenetrating co-continuous ceramic and metal phases. By controlling the composition and microstructure of the precursor and the composition of the reaction bath, one can control the structure and properties of the resulting material. This paper summarizes preliminary attempts to use these routes to create next-generation materials for automotive brake rotors. Two types of materials were tested. The first is a two-level composite of a co-continuous alumina-aluminum structure that surrounds SiC particles that provide thermal conductivity. For higher-temperature use, the aluminum alloy is replaced with aluminum-bronze. Both materials show friction and wear properties similar to cast iron, but with half the density and better thermal conductivity.     

In-process exothermic reaction in high-velocity oxyfuel and plasma spraying with SiO<Subscript>2</Subscript>/Ni/Al-Si-Mg composite powder

Reactive thermal spraying, in which thermodynamically stable compounds are formed by expected inprocess reactions, has attracted considerable attention as a result of the wide availability of in situ composite coatings. Such in-process reactions occur differently in high-velocity oxyfuel (HVOF) and plasma spraying because of differences in the flame temperature and speed. In the current study, a composite powder of SiO₂/Ni/Al-Si-Mg was deposited onto an aluminum substrate to fabricate in situ composite coatings by both spraying methods. The coating hardness sprayed with Al-Si-Mg core powder increases with silicon and magnesium content, whereas the coatings by HVOF spraying show higher hardness than those by plasma spraying. In the present reactive spraying, the exothermic reaction of SiO₂ with molten Al-Si-Mg alloy leads to composite materials of MgAl₂O₄, Mg₂Si, and Al-Si matrix. Moreover, a rapid formation of aluminide (NiAl₃), which is introduced by an exothermic reaction of plated nickel with Al-Si-Mg core powder, enhances the reduction of SiO₂, especially in HVOF spraying. A series of in-process reactions proceed mainly during splat layering on a substrate instead of during droplet flight even in plasma spraying. Plasma-sprayed composite coatings become much harder because of the great progress of in-process reactions.     

Soldering mechanisms in materials and coatings for aluminum die casting

The stability against reaction with aluminum of materials and coatings commonly used in aluminum die casting was investigated. The materials considered here were H13 tool steel and Anviloy® 1150, whereas the coatings were TiN and CrN. Special model, freestanding, multilayered thin film structures were used in this study, in association with complementary differential scanning calorimetry and X-ray diffraction. The nature of the reactions (endo or exothermic) and their onset temperatures up to 1273 K were determined. Based on of these results, some activation energies for the different reactions taking place between aluminum and die material or between aluminum and coatings could be established. Different intermetallic compounds were formed in these reactions, which were identified by post mortem X-ray diffraction analysis. Anviloy® 1150 showed superior stability as compared to H13 tool steel, whereas CrN was more inert than TiN coatings. CrN exhibited the best performance among all materials and coatings considered here, although its practical application relies also on adhesion of the CrN coating to the die bulk material. The results are discussed on the lights of two recent models for soldering in aluminum die casting.     

Effects of aluminum concentration and compact thickness on reaction synthesis of Ni3Al---NiAl alloys

The effects of aluminum concentration and green compact thickness on the reaction synthesis of powder compacts containing 25 to 40 at. %Al were studied under a uniaxial compressive stress of 10 MPa. The results indicate that both reaction product and material density are sensitive to these two parameters. For all powder compacts with a thickness of 5 mm, no temperature increase was detected during reaction synthesis, indicating no formation of transient liquid phases and thus no self-sustaining combustion reaction. For 6- and 7-mm-thick compacts containing 40% Al, a full synthesis reaction took place, resulting in production of the NiAl alloy with a high material density (>98%) and a fine grain size (14 μm). Other compacts containing 25 and 30% Al showed a coexistence of partially and fully reacted zones, with the reaction zone size strongly dependent on aluminum concentration and compact thickness. All the results are discussed in terms of local heat accumulation and heat transfer as well as thermodynamic analyses of exothermic reactions during each reaction step.     

Effect of carbon content on microstructure of in-situ Al_2O_(3p)-TiC_p/Al composites

1　ＩＮＴＲＯＤＵＣＴＩＯＮＸＤｔｅｃｈｎｉｑｕｅｉｓａｐａｔｅｎｔｏｆＭａｒｔｉｎＭａｒｉｅｔｔａＣｏｒ ｐｏｒａｔｉｏｎ[1] .Ｃｏｍｐｏｓｉｔｅｓｆａｂｒｉｃａｔｅｄｂｙｔｈｉｓｔｅｃｈｎｉｑｕｅｐｏｓｓｅｓｓｍａｎｙａｄｖａｎｔａｇｅｓ :1)Ｔｈｅｓｙｎｔｈｅｓｉｚｅｄｒｅｉｎ ｆｏｒｃｅ ｐａｒｔｉｃｌｅｓａｒｅｆｉｎｅｉｎｓｉｚｅａｎｄｅｑｕｉａｘｅｄｉｎｓｈａｐｅ[2 ,3 ] ;2 )Ｔｈｅｉｎｔｅｒｆａｃｉａｌｃｏｍｐａｔｉｂｉｌｉｔｙｂｅｔｗｅｅｎｉｎ ｓｉｔｕｒｅｉｎｆｏｒｃｅｐａｒｔｉｃｌｅｓ…     

The intelligent processing of materials: An overview and case study

The intelligent processing of materials is an emerging methodology for simulating and controlling the processing and manufacture of materials. It involves model-based process optimization, in-situ microstructure sensing, and the control of both the process variables and the performance-defining microstructural attributes of a material during its synthesis and processing. It is finding widespread application in the manufacture of electronic, photonic, and composite (i.e., high-performance) materials, as well as primary metals. Authors’ Note: This article is based on AGARD SMP lecture series 205, Smart Structures and Materials: Implications for Military Aircraft of New Generation, held in Philadelphia, Pennsylvania, on October 30–31, 1996; in Amsterdam, Netherlands, on November 18–19, 1996; and in Paris on November 21–22, 1996. Haydn N.G. Wadley earned his Ph.D. in physics at the University of Reading, England, in 1979. He is currently the Edgar A. Starke, Jr., research professor in materials science and associate dean for research at the School of Engineering and Applied Science at the University of Virginia. Dr. Wadley is a member of TMS. Ravi Vancheeswaran earned his Ph.D. in mechanical and aerospace engineering at the University of Virginia in 1996. He is currently a research assistant professor at the School of Engineering and Applied Science at the University of Virginia. Dr. Vancheeswaran is also a member of TMS.     

Development of freeform fabrication method for Ti–Al–Ni intermetallics

A new droplet-based reactive rapid prototyping (RRP) method for making intermetallic parts is demonstrated. This method combines the processes of solid freeform fabrication (SFF) and combustion synthesis (CS). Intermetallic beads are produced by the CS reaction. These synthesized beads are assembled and joined by using the SFF technique with the aid of heat released from exothermic reactions. The intermetallic compound of Ti–Al–Ni is chosen to demonstrate this method. Ni was added to the Ti–Al system to enhance the reaction. Thermodynamics of the Ti–Al–X·NI (X=5, 10, 15 wt.%) system are calculated. The effects of the addition of Ni in powder bed and heating temperature of aluminum droplets on the width and thickness of the reacted area were investigated. As an example, a Ti–Al–Ni intermetallic bar with simple shape was fabricated as a demonstration of RRP.     

Strategies for designing composite materials for high temperature application

A clear understanding of the factors controlling reproducible composite processing is critical for high temperature application. One approach to obtain stable phase combinations (i.e. compatibility) is to use a controlled interface reaction (in-situ layer design). An effective approach to control the reaction products and diffusion pathway by adding an extra component layer has been practiced and analyzed based upon the relative component fluxes. At the same time, the observed diffusion pathway has been examined in terms of a chemical potential framework, which can provide in assistance interpreting kinetic data in multicomponent systems. While component chemical potential values can increase and decrease through the interdiffusion reaction layers, the total free energy value will be decreased during the interdiffusion reaction. In order to examine the operating principles involved in the synthesis of in-situ composites, model ternary systems including potential materials such as TiAl and SiC have been investigated. This article based on a presentation made in the symposium “The 1999 KSEA Materials Symposium in Honor of Professor Sang Joo Kim’s 70th Anniversary“, held at UCLA, Los Angeles, CA, USA, August 12–14, 1999 under the auspices of Korea—US American Scientists and Engineers Association.     

Synthesis of TiCr<Subscript>2</Subscript> intermetallic compound from mechanically activated starting powders via calcio-thermic co-reduction

Effect of mechanical activation of TiO2 and Cr2O3 oxides as starting materials was investigated for direct synthesis of TiCr₂. Differential thermal analysis (DTA) indicated that increasing the ball milling time resulted in lower exothermic reaction temperatures between molten Ca–Cr2O3 and molten Ca–TiO2. A model-free Kissinger type method was applied to DTA data to evaluate the reaction kinetics. The results reveal that the activation energy of the exothermic reactions decreased with increasing the milling time. The structure, oxygen content, and average particle sizes of the obtained TiCr₂ product were affected by the ball milling time of the starting materials. Increasing the milling time from 10 to 40 h decreased the average particle size and oxygen content of the obtained TiCr₂ from 10 to 2 μm and from 1690 to 1290 ppm, respectively. The X-ray diffraction (XRD) results showed that TiCr₂ compounds with metastable bcc phase can be produced using nano-sized starting materials, while only a slight amount of bcc phase can be obtained in the TiCr₂ compounds, using micron-sized starting materials. The TiCr₂ obtained by this method had a hydrogen absorption capability of 0.63 wt % and the kinetics of the hydrogen absorption increased for the 40 h milled sample.     

Microstructure evolution during preparation of in-situ TiB reinforced titanium matrix composites

1　INTRODUCTIONTitaniummatrixcompositesarepromisingmate rialswhichcanbeusedextensivelyinaerospaceandautomotiveindustriesbecauseoftheirexcellentme chanicalpropertiesatroomtemperatureandelevatedtemperature[14 ] ,suchaslowdensity ,highstrength ,andcorrosion resistance .Amongthein situfabrica tionmethodsoftitaniummatrixcomposites[511] ,self propagatinghigh temperaturesynthesis (SHS )methodhasuniqueadvantage ,thatis ,thereinforce mentsarefineanddispersed .InSHS ,thereisanexothermicreactionac…     

Structural steels with a structure of a natural composite and evaluation of their properties

Composite materials are known to be formed by a three-dimensional combination of components with different properties. In fiber composite materials the reinforcing components are one- or two-dimensional. It often happens that the structural components of a steel are arranged as in a fiber composite material (i.e., in the form of fibers directed along the rolling path). The difference in the components in such steels residues not only in their chemical composition, as in composite materials, but also in their structure. Such steels can be called materials with a natural composite structure, which in fact does not change anything. The present work is devoted to three kinds of structural steel with a structure of a natural composite.Translated from Metallovedenie i Tetmicheskaya Obrabotka Metallov, No. 8, pp. 19 – 22, August, 1996.     

Microwave-assisted combustion synthesis in a mechanically activated Al-TiO2-H3BO3 system

The Al₂O₃-TiB₂ in-situ composite has been fabricated by different techniques. In this work, the mechanical activation process has been used to aid microwave-assisted combustion synthesis (MACS) to produce the Al₂O₃-TiB₂ in-situ composite. For this purpose, the thermite mixture of Al, TiO₂ and boric acid (H₃BO₃) powders was used as the raw materials, and was mechanically activated at different milling speeds. The results of X-ray phase analysis of the mechanically activated samples after combustion synthesis showed that the Al₂O₃-TiB₂ in-situ composite has been successfully fabricated by thermal explosion mode of combustion synthesis in microwave, while no combustion synthesis occurred for the unmilled sample. Also, it was found that by increasing the milling speed from 250 to 400 rpm, the purity of the final products has been increased; while further milling speed up to 550 rpm reduced the purity of the final products. The effects of milling speed were also studied by means of differential scanning calorimetry (DSC) measurements. It was shown that by increasing the energy level of the reactants via milling speed, the ignition temperature and the intensity of exothermic peaks in the DSC curves have been changed. Finally, in order to have a good understanding about the in-situ formation of such ceramic composites, a reaction mechanism was proposed based on the experimental results. The synthesized composite exhibited high microhardness value of about 1950 Hv in dense parts.     

钙长石/莫来石复相耐高温材料的物相设计

以高铝矾土、苏州土、蓝晶石、和半水石膏为主要原料,添加Ca(OH)_2作为钙源,进行了钙长石莫来石复相耐高温材料的物相设计.利用XRD和SEM研究了不同的原料配比、合成温度对高温固相合成钙长石莫来石复相耐高温材料的物相和显微结构的影响.结果表明,在1400 ℃保温3 h,原料通过高温固相反应法可以得到钙长石和莫来石为主要物相的复相耐高温材料.     

W骨架/Zr基非晶合金复合材料破片冲击释能特性研究

采用准密封箱冲击超压实验,研究了W骨架/Zr基非晶合金复合材料的在不同冲击速度下和靶板厚度下的冲击释能特性。并根据温度控制含能结构材料冲击诱发化学反应的热动力学理论,拟合了材料反应的表观活化能E_a和反应系数n,分析了材料的热化学反应特性。结果表明,材料冲击超压峰值与冲击速度正相关,其激发反应阈值为766m/左右,在相同速度下,有使破片靶后释能效率最大化的最优靶板厚度,但在8mm厚钢靶范围内,前板厚度对冲击释能特性影响不大。材料冲击激发化学反应的冲击压力阈值P_c=18.37GPa,对应的理论温度阈值T_c=3736.6K。材料反应效率随着冲击压力和击波温度的增加而增加,在40GPa冲击压力范围内,材料并未完全反应,其理论反应效率达到61.5%。     

Manufacture and properties of composite coatings: An introduction

Composite layers are capable of varying surface properties of parts over wide ranges. The galvanic route and thermal spraying are predestined to create composite layers. Wear resistance can be realized by a metallic matrix and nonmetallic reinforcing component that serves as a disperse phase. The goal of this article is to report on experimental results gained from samples produced galvanically. Improved wear resistance and hardness of the composite layers are main topics. The thermal spray process requires more sophisticated processing techniques if the desired components cannot be supplied by individual injectors or mechanically premixed. In cases where pneumatic material feed (e.g., carbon short fibers) is not possible, the material supply must be achieved by agglomerated powders containing the second phase as a constituent. Suitable agglomerated powders allow a control of thermal decomposition of the sprayed materials by using additives as admixture to the agglomerate. Practical examples are outlined in the article.     

7150 Al-Zn-Mg合金固态反应动力学参数的测定

采用差示扫描量热法（DSC）,在不同加热速率下研究7150 Al-Zn-Mg合金在水淬、自然时效和人工时效状态下的固态反应。DSC曲线上不同的放热和吸热峰对应着不同的固态反应阶段。随着加热速率的增加,各个峰位对应的温度也随之增加,表明这些固态反应是热力学活化和动力学控制的。通过测量不同时效时间下合金的硬度来评估合金的时效行为。通过分析DSC曲线各个峰位对应的热流,得到了合金固态反应的相变分数（Y）、相变速率（dY/dt）、相变函数（f（Y））和动力学参数（活化能Q、频率因子k0）。结果表明：所得到的这些动力学参数与已有文献所报道的结果吻合较好。     

耐环境涂层厚度对复合材料性能的影响

目的选用复合材料用耐环境涂层体系的最优厚度使用比例,提高复合材料的综合力学性能和耐湿热性。方法针对复合材料用底漆/面漆涂层体系,通过控制喷涂工艺将涂层的厚度控制转化为层数控制,设计4组不同层数的底漆/面漆涂层,对单层和多层复合材料用抗腐蚀涂层体系的柔韧性、附着力、冲击性能以及耐湿热性能进行了系统表征。结果随着涂层厚度的增加,涂层体系的柔韧性、附着力、耐冲击性能均有所降低。涂层通过隔绝水环境与复合材料的直接接触,有效降低了吸湿速率,具有较好的湿热防护性能,随着涂层厚度的增加,耐湿热性提高。涂层体系的柔韧性、附着力、耐冲击性能以及耐环境性能与厚度之间并非简单的线性关系。结论通过控制涂层单层厚度将厚度优化转变为层数优化,提出了一种有机涂层厚度优化的试验方案,并确定(1×2)厚度设计下涂层兼具较优的力学性能和耐湿热性能。     

微量合金元素对硬质合金性能的影响

为改善金属-陶瓷复合材料的物理、化学及机械性能,通常会在其中添加微量合金元素,然而如果添加方法不同、或后续处理方法不当,则合金元素的功效无法完全发挥,甚至会出现负面效应。而这些最终都可归结到对微量元素的精确控制。硬质合金属于金属-陶瓷复合材料中最重要的材料之一。详细概括了常见的微量合金元素对硬质合金的制备、组织结构和性能的影响。分析研究了微量合金元素的来源、在硬质合金中的作用机理,及其精确控制难点。根据其作用机理,提出一些可能的有效措施,用于精确控制微量合金元素在硬质合金中的含量、相组成、存在状态、分布等,以期能为硬质合金的生产实际提供一些理论指导。     

Nickel sulfide-based energy storage materials for high-performance electrochemical capacitors

Supercapacitors are favorable energy storage devices in the field of emerging energy technologies with high power density,excellent cycle stability and environmental benignity.The performance of supercapacitors is definitively influenced by the electrode materials.Nickel sulfides have attracted extensive interest in recent years due to their specific merits for supercapacitor application.However,the distribution of electrochemically active sites critically limits their electrochemical performance.Notable improvements have been achieved through various strategies such as building synergetic structures with conductive substrates,enhancing the active sites by nanocrystallization and constructing nanohybrid architecture with other electrode materials.This article overviews the progress in the reasonable design and preparation of nickel sulfides and their composite electrodes combined with various bifunctional electric double-layer capacitor(EDLC)-based substances(e.g.,graphene,hollow carbon) and pseudocapacitive materials(e.g.,transition-metal oxides,sulfides,nitrides).Moreover,the corresponding electrochemical performances,reaction mechanisms,emerging challenges and future perspectives are briefly discussed and summarized.