Sintering behavior of spark plasma sintered alumina with graphene nanoplatelet reinforcement

Graphene nanoplatelet (GNP) reinforced alumina is synthesized by spark plasma sintering (SPS) using process conditions of 1100–1500 °C, 3–10 min dwell time, and 45–90 MPa in order to investigate the effects of GNP on sintering behavior. High volume fractions of GNP (5–15 vol%) are utilized in order to accentuate effects of GNPs. GNP effects on sintering behavior are assessed by evaluating microstructural evolution, grain growth kinetics, and microhardness. The addition of GNPs is found to suppress grain growth by a grain wrapping mechanism resulting in a 10% increase in activation energy when GNP content is increased beyond 5 vol %. Grain growth suppression partially mitigates a decrease in hardness due to the introduction of the soft GNP phase. Evidence of GNPs serving as a sintering aid are seen at short sintering times (3 min), while densification and grain size are observed to level off with extended sintering time (10 min). The application of higher pressures enhances densification, which enables GNPs to more effectively wrap around grains resulting in enhanced grain growth suppression.     

Remarkable improvement in tribological behavior of plasma sprayed carbon nanotube and graphene nanoplatelates hybrid reinforced alumina nanocomposite coating

Addition of 0.5?wt% of graphene nanoplatelates (GNPs) and 1?wt% carbonnanotube (CNTs) in plasma sprayed Al₂O₃ coating showed the reduction of 93.25% in wear volume loss and 90.94% in wear rate. This could be attributed to the simultaneous effect of enhanced densification, presence of the transferred layer from the counterpart, strong interface between Al₂O₃, GNP and CNTs and toughening offered by the GNPs and CNTs. The lowest COF value of 0.27 was recorded on addition of 0.5?wt% of GNP in Al₂O₃ coating, which could be attributed to the graphitic lubrication on the worn track during the wear.     

Scratch behavior of boron nitride nanotube/boron nitride nanoplatelet hybrid reinforced ZrB2-SiC composites

Spherical instrumented scratch behavior of ZrB₂-SiC composites with and without hybrid boron nitride nanotubes (BNNTs) and boron nitride nanoplatelets (BNNPs) was investigated in this research. Typical brittle fracture such as microcracks both in and beyond the residual groove and grain dislodgement was observed in ZrB₂-SiC composite, while hybrid BN nanofiller reinforced ZrB₂-SiC composite exhibited predominantly ductile deformation. The peculiar three-dimensional hybrid structure in which BNNPs retain their high specific surface area and de-bundled BNNTs extend as tentacles contributes to the improved tolerance to brittle damage. Additionally, easier grain sliding due to BN hybrid nanofillers located at grain boundaries and these BN hybrid nanofillers attached on the scratch surface would provide significant self-lubricating effect to reduce lateral force during scratch and to alleviate contact damage.     

Microstructure and physicomechanical properties of pressureless sintered multiwalled carbon nanotube/alumina nanocomposites

Multiwalled carbon nanotube (MWCNT)/alumina (Al₂O₃) nanocomposites containing CNT from 0.15 vol.% to 2.4 vol.% have been successfully fabricated by simple wet mixing of as-received commercial precursors followed by pressureless sintering. Extent of densification of nanocomposites sintered at low temperature (e.g. 1500 °C) was <90%, but increased up to ∼99% when sintered at 1700 °C and offered superior performance compared to pure Al₂O₃. Nanocomposites containing 0.3 vol.% MWCNT and sintered at 1700 °C for 2 h in Argon led to ∼23% and ∼34% improvement in hardness and fracture toughness, respectively, than monolithic Al₂O₃. In addition, the highest improvement (∼20%) in bending strength was obtained for 0.15 vol.% MWCNT/Al₂O₃ nanocomposite compared to pure Al₂O₃. Weibull analysis indicated reliability of nanocomposites increased up to 0.3 vol.% MWCNT, whereas, beyond that loading consistency was the same as obtained for pure Al₂O₃. Detailed microstructure and fractographic analysis were performed to assess structure-property relationship of present nanocomposites.     

Preparation and mechanical properties of alumina composites reinforced with nickel-coated graphene

This paper discusses the influence of nickel–phosphorus coated graphene (Gn–Ni–P) and uncoated graphene (Gn) addition to an alumina matrix and its impact on the mechanical properties of obtained composites. The composites are prepared via powder processing and consolidated using the Spark Plasma Sintering (SPS) method. The effects of the addition of coated graphene and coating thickness on mechanical properties were evaluated. Physical properties such as relative density, hardness and fracture toughness were analyzed. Significant improvement of the fracture toughness (60%) for the composites with 2 vol% Gn–Ni–P compared to reference sample was observed. Moreover, 35% higher K_IC was noticed for Gn–Ni–P reinforced composites than for Al₂O₃–Gn.     

Mechanical properties of graphene platelet-reinforced alumina ceramic composites

Alumina (Al₂O₃) ceramic composites reinforced with graphene platelets (GPLs) were prepared using Spark Plasma Sintering. The effects of GPLs on the microstructure and mechanical properties of the Al₂O₃ based ceramic composites were investigated. The results show that GPLs are well dispersed in the ceramic matrix. However, overlapping of GPLs and porosity within ceramics are observed. The flexural strength and fracture toughness of the GPL-reinforced Al₂O₃ ceramic composites are significantly higher than that of monolithic Al₂O₃ samples. A 30.75% increase in flexural strength and a 27.20% increase in fracture toughness for the Al₂O₃ceramic composites have been achieved by adding GPLs. The toughening mechanisms, such as pull-out and crack deflection induced by GPLs are observed and discussed.     

Phase analysis and wear behavior of in-situ spark plasma sintered Ti3SiC2

In-situ synthesis of dense near-single phase Ti₃SiC₂ ceramics from 3Ti/SiC/C/0.15Al starting powder using spark plasma sintering (SPS) at 1250 °C is reported. Systematic analysis of the phase development over a range of sintering temperatures (1050–1450 °C) suggested that solid state reactions between intermediate TiC and Ti₅Si₃ phases lead to the formations of Ti₃SiC₂. The effect of starting powder composition on phase development after SPS at 1150 °C was also investigated using three distinct compositions (3Ti/SiC/C, 2Ti/SiC/TiC, and Ti/Si/2TiC). The results indicate that the starting powder compositions, with higher amounts of intermediate phase such as TiC, favor the formation of Ti₃SiC₂ at relatively lower sintering temperature. Detailed analysis of wear behavior indicated that samples with higher percentage of TiC, present either as an intermediate phase or a product of Ti₃SiC₂ decomposition, exhibited higher microhardness and better wear resistance compared to near single phase Ti₃SiC₂.     

Wear resistant boron carbide compacts produced by pressureless sintering

Boron carbide compacts were produced by pressureless sintering at 2200 °C/2 h and 2250 °C/2 h in Ar atmosphere, using a starting powder with a particle size smaller than 3 µm. Effects of carbon addition (3.5 wt%) and methanol washing of the starting powder were investigated on the densification, Vickers hardness, and micro-abrasive wear resistance of the samples. The removal of oxide phases by methanol washing allowed the production, with no sintering additive, of highly densified (93.6% of theoretical density), hard (25.4 GPa), and highly wear resistant (wear coefficient =2.9×10^–14 m³/N.m) boron carbide compacts sintered at 2250 °C. This optimized combination of properties was a consequence of a reduced grain growth without the deleterious effects associated to the carbon addition. Methanol washing of the starting powder is a simple and general approach to produce, without additives, high quality, wear resistant boron carbide compacts by pressureless sintering.     

Wear properties and microstructures of alumina matrix composite ceramics used for drawing dies

The alumina matrix ceramics used for drawing dies were prepared by hot-press sintering method. The ceramics materials were made of Al₂O₃/TiC, Al₂O₃/(W,Ti)C and Al₂O₃/Ti(C,N). Mechanical and friction properties of these materials were tested and measured. The experiments for testing friction properties were carried on wear and tear machine. Mechanisms of frictions were analyzed with scanning electron microscope. Results showed that the alumina matrix composite ceramics have good physical and mechanical properties for used as drawing dies. Measured friction coefficients of alumina matrix composite ceramics showed a trend of decline and kept the value of 0.4–0.5 with the rotating speed of 550 rpm. Alumina matrix composite ceramics have smaller wear rate, while the wear rates of Al₂O₃/TiC and Al₂O₃/(W,Ti)C decrease gradually with a rising rotation speed. The wear of alumina matrix ceramics was severe at deformation zone. The primary wear behaviors of alumina matrix ceramics are scraping and furrowing. Even though the mechanisms for wear different, abrasive and adhesive wear were found to be the predominant wear mechanisms for the ceramic drawing die.     

Microstructure and electrical properties of zirconia and composite nanostructured ceramics sintered by different methods

The aim of this study is the preparation and characterization of dense cubic zirconia ceramics and zirconia nanocomposites (reinforced with 5 wt% alumina). The powders were obtained through sol–gel methods and densified using classical sintering and spark plasma sintering (SPS) methods. The obtained ceramics were characterized through X-ray diffraction, scanning electron microscopy and impedance spectroscopy at room and high temperature. The average grain size of cubic zirconia particles was found to be approximately 8 and 2.5 μm for the classical sintering and 99 nm for SPS. The alumina particles in composites have an average grain size of 0.7 μm for classical sintering and 53 nm for SPS ones. The total conductivity for nanocomposites sintered through both methods was also determined.     

Preparation of self-lubricating porous alumina ceramics with PMMA /PAO6 microcapsules and their tribological properties

In this work, we showed that immersing polymethyl methacrylate (PMMA)/poly alpha olefins (PAO6) microcapsules into the porous matrix can improve the lubrication properties of porous alumina ceramics dramatically. PMMA/PAO6 microcapsules were synthesized by microemulsion polymerization, and the microcapsules were immersed in the porous alumina ceramic matrix by vacuum impregnation. The lubrication behaviors of the porous alumina ceramics with PMMA/PAO6 microcapsules have been investigated under different loads. As compared with the unprocessed porous alumina ceramics, the coefficient of friction (COF) of the porous ceramics impregnated with microcapsules could be reduced to 4% of that without microcapsules, and the wear rate could be reduced by two orders of magnitude. No obvious change of the COF was noticed for the matrices with different pore sizes. The good self-lubrication properties were achieved by releasing the PAO6 in the microcapsules during the friction process.     

Ablation behavior and mechanism of SiCf/Cf/SiBCN ceramic composites with improved thermal shock resistance under oxyacetylene combustion flow

The ablation properties and mechanisms (under oxyacetylene combustion) together with thermal shock behavior of SiC_f/C_f/SiBCN ceramic composites were investigated. The solid ablation products are primarily amorphous SiO₂ and cristobalite. The primary ablation mechanisms include fiber and ceramic matrix oxidation, evaporation of B₂O₃ (l) and SiO₂ (l), and mechanical exfoliation. SiC_f/C_f/SiBCN has a significantly low mass ablation rate and a desirable linear ablation rate. The combination of crack deflection caused by SiC and carbon fibers, fiber pull-out and debonding improves thermal shock resistance and thus leads to the absence of surface macrocracks.     

Solvothermal synthesis of SnO2/graphene nanocomposites for supercapacitor application

A facile solvent-based synthesis route based on the oxidation–reduction reaction between graphene oxide (GO) and SnCl₂·2H₂O has been developed to synthesize SnO₂/graphene (SnO₂/G) nanocomposites. The reduction of GO and the in situ formation of SnO₂ nanoparticles were achieved in one step. Characterization by X-ray diffraction (XRD), ultraviolet-visible (UV–vis) absorption spectroscopy, Raman spectroscopy, and field emission scanning electron microscopy (FESEM) confirmed the feasibility of using the solvothermally treated reaction system to simultaneously reduce GO and form SnO₂ nanoparticles with an average particle size of 10 nm. The electrochemical performance of SnO₂/graphene showed an excellent specific capacitance of 363.3 F/g, which was five-fold higher than that of the as-synthesized graphene (68.4 F/g). The contributing factors were the synergistic effects of the excellent conductivity of graphene and the nanosized SnO₂ particles.     

Sintering behavior of nanostructured WC-Co composite

Sintering of nanocrystalline WC-Co, retaining the nanoscaled grain sizes is a matter of great interest. Many non traditional methods have been used to achieve this goal as the required result has not been achieved using the traditional method of liquid phase sintering. The present study is an attempt to find out the limitations of traditional sintering method and optimize it to get nanocrystalline WC-Co composites. The effect of temperature, time and composition variation has been studied to see the sintering behavior of nanostructured WC-Co composite. Detailed X-ray diffraction (XRD) analysis as well as microstructural examination showed that sintering at 1350 °C for 1 h with 5% binder composition (Co) is a set of critical temperature, time and composition which can provide the required results. The grain growth is through coalescence. At critical conditions the majorities of WC grains are faceted and attains the shape of prismatic and basal facets.     

Synthesis and properties of ceramic-based nanocomposite layer of aluminum carbide embedded with oriented carbon nanotubes

In the present work, carbon nanotubes (CNTs) were embedded in aluminum carbide coating in desired vertical/horizontal direction in order to fabricate a nanocomposite layer with unidirectional enhanced mechanical properties. A novel method based on monopolar pulsed plasma electrolysis under magnetic field was used for this purpose. Nanostructure of the obtained nanocomposite layer was examined with high precision figure analysis of SEM, AFM and TEM nanostructures. The mechanical and tribological properties of these coatings were investigated with respect to the direction of the embedded CNTs. The coefficient of friction was lowered from 0.2 to less than 0.1 in a pin-on-disc test against steel with dramatic affected coating wear rate by a decrease to near 400% with respect to raw substrate. The lower friction is attributed to more extensive creation of amorphous carbon on the counter surface and also in the coating wear track. As a conclusion, this method is appropriate for fabrication of hard coating on the surface of low-melting-point metals and light alloys.     

Scratch behaviour of graphene alumina nanocomposites

The scratch resistance behaviour of alumina-graphene nanoplatelet (GNP) (0.5, 2 and 5?vol.-%) composites was investigated using a Rockwell indenter with normal applied loads ranging from 1 to 200?N. The alumina-GNP composites behaved differently during scratch testing depending on the normal applied load. The coefficient of friction of the composites did not change much at low normal loads but increased with increasing amount of GNP in the alumina matrix for high normal loads. The addition of GNP contributed to improved scratch resistance of alumina nanocomposites only for low loads below ～97?N. This correlates with the mechanical properties of the composites. As the applied load increased, the scratch resistance of the GNP composites decreased due to the presence of weakly bonded grain boundaries in the alumina matrix, which enhanced chipping of material.     

Microstructure stabilization of a novel glass/YSZ composite coating material by adding alumina particles

Glass-based composite coating materials incorporating particles of alumina or YSZ were prepared by reaction sintering. It was revealed that phase evolution played a key role on thermal expansion behavior of the composite coating materials. Both precipitating of t-ZrO₂ crystals and adding YSZ inclusions could raise CTEs of the glass-based matrix, while the formation of zircon produced the reverse effect. Especially, alumina additives retarded the crystallization of the base glass and reduced reaction rates between YSZ and the glass matrix remarkably. Thus, the Al₂O₃/YSZ/glass tri-composites could serve as an environmental barrier coating for intermetallics and superalloys because of the stabilized microstructure.     

Spark plasma sintering of self-propagating high-temperature synthesized TiC0.7/TiB2 powders and detailed characterization of dense product

In this work, the fabrication of bulk TiC_0.7/TiB₂ nanostructured composites through metastable transformation processing is investigated by taking advantages of two non-conventional powder metallurgy methods. First, the highly metastable TiC_0.7/TiB₂ agglomerated powders are synthesized by the so-called self-propagating high-temperature synthesis (SHS), followed by rapid quenching. Then, the spark plasma sintering (SPS) method is adopted to consolidate the SHSed powders.A bulk ceramic composite with nanocrystalline microstructure characterized by a high-relative density is then obtained. Dwell temperature of 1400 °C, heating time of 3 min, and total processing time equal to 5 min, while applying a mechanical pressure of 20 MPa, are found to be the optimal SPS experimental conditions in order to obtain near-fully densified samples.The obtained TiC_0.7/TiB₂ samples exhibit hardness HV5 as high as 24 GPa, modulus of elasticity of about 400 GPa, fracture toughness of about 5.6 MPa m^1/2, and a compressive strength of about 2.9 GPa. A very low-wear rate (W_v = 3.8 × 10⁻⁶ mm³/(N m)) and a good thermal shock resistance (ΔT_c = 250 °C) are also displayed. In addition, a high-abrasive wear factor (AWF) equal to 1.84 is evaluated on the basis of the achieved mechanical properties. These results make the obtained TiC_0.7/TiB₂ composite suitable for wear resistant parts as well as cutting tool materials.     

Electroconductive composite of zirconia and hybrid graphene/alumina nanofibers

Novel type of hybrid nanofillers representing graphene encapsulated alumina nanofibres was selected as an additive to develop toughened electroconductive partially stabilized zirconia. The sinterability, mechanical and electrical properties of the produced nanocomposites were studied as function of the filler/graphene content. Composites containing just 0.6 vol.% of graphene corresponding to 3 vol.% of hybrid nanofibres exhibited high electroconductivity of 58 S/m without deterioration of mechanical properties. They also showed a slight toughening effect that is reflected by an increase in the indentation fracture toughness by 20% as compared to monolithic zirconia.     

Mechanical properties and rapid consolidation of binderless nanostructured tantalum carbide

The rapid sintering of nanostructured TaC hard material was investigated with a focus on the manufacturing potential of high-frequency induction heated sintering process. The advantage of this process is that it allows very quick densification to near theoretical density and prohibition of grain growth in nanostructured materials. A dense pure TaC hard material with a relative density of up to 96% was produced with simultaneous application of 80 MPa pressure and induced current within 3 min. The finer the initial TaC powder size, the higher the density and the better mechanical properties. The fracture toughness and hardness values obtained from 10 h milled powder were 5.1 ± 0.3 MPa m^1/2 and 22 GPa, respectively, under 80 MPa pressure and 80% output of total power capacity (15 kW).