Investigation of carbon nanotube reinforced aluminum matrix composite materials

We have increased the tensile strength without compromising the elongation of aluminum (Al)–carbon nanotube (CNT) composite by a combination of spark plasma sintering followed by hot-extrusion processes. From the microstructural viewpoint, the average thickness of the boundary layer with relatively low CNT incorporation has been observed by optical, field-emission scanning electron, and high-resolution transmission electron microscopies. Significantly, the Al–CNT composite showed no decrease in elongation despite highly enhanced tensile strength compared to that of pure Al. We believe that the presence of CNTs in the boundary layer affects the mechanical properties, which leads to well-aligned CNTs in the extrusion direction as well as effective stress transfer between the Al matrix and the CNTs due to the generation of aluminum carbide.     

机械合金化与放电等离子烧结制备Fe-Fe3Al材料

为开发新型金属材料,采用机械合金化与放电等离子烧结的方法制备Fe-Fe3Al合金.根据Fe-Al二元相图与研究经验,对成分及工艺进行优化设计.用X射线衍射仪(XRD)对成分进行了定性分析,用扫描电子显微镜(SEM)观察了样品的表面与断口形貌,进行了能谱分析,并测试了致密度、显微硬度(HV)及抗弯强度、抗拉强度等力学性能.结果表明:对粉末进行预球磨,并在球磨前后对粉末进行搅拌混合处理,能更好地促使Fe与Al在高能球磨的过程中反应;经放电等离子烧结能够制备出Fe3Al/Fe两相材料,相对密度为99%以上,硬度为HV561,抗弯强度1426 MPa,抗拉强度640 MPa,力学性能优于文献报道的值.     

Dual-nanoparticulate-reinforced aluminum matrix composite materials

Aluminum (Al) matrix composite materials reinforced with carbon nanotubes (CNT) and silicon carbide nanoparticles (nano-SiC) were fabricated by mechanical ball milling, followed by hot-pressing. Nano-SiC was used as an active mixing agent for dispersing the CNTs in the Al powder. The hardness of the produced composites was dramatically increased, up to eight times higher than bulk pure Al, by increasing the amount of nano-SiC particles. A small quantity of aluminum carbide (Al(4)C(3)) was observed by TEM analysis and quantified using x-ray diffraction. The composite with the highest hardness values contained some nanosized Al(4)C(3). Along with the CNT and the nano-SiC, Al(4)C(3) also seemed to play a role in the enhanced hardness of the composites. The high energy milling process seems to lead to a homogeneous dispersion of the high aspect ratio CNTs, and of the nearly spherical nano-SiC particles in the Al matrix. This powder metallurgical approach could also be applied to other nanoreinforced composites, such as ceramics or complex matrix materials.     

Tensile properties of carbon nanotube reinforced aluminum nanocomposite fabricated by plasma spray forming

Uniaxial tensile tests were performed on plasma spray formed (PSF) Al–Si alloy reinforced with multiwalled carbon nanotubes (MWCNTs). The addition of CNTs leads to 78% increase in the elastic modulus of the composite. There was a marginal increase in the tensile strength of CNT reinforced composite with degradation in strain to failure by 46%. The computed critical pullout length of CNTs ranges from 2.1 to 19.7 μm which is higher than the experimental length of CNT, leading to relatively poor load transfer and low tensile strength of PSF nanocomposites. Fracture surface validates that tensile fracture is governed strongly by the constitutive hierarchical microstructure of the plasma sprayed Al–CNT nanocomposite. The fracture path in Al–CNT nanocomposite occurs in Al–Si matrix adjacent to SiC layer on CNT surface.     

Microstructure and Properties of Spark Plasma Sintered Carbon Nanotube Reinforced Aluminum Matrix Composites

In this paper, spark plasma sintering (SPS) of multi‐walled carbon nanotube (CNT) reinforced aluminum matrix composites is reported. Ball milling of the Al‐CNT mixture with polyacrylic acid (PAA) dispersion agent followed by SPS resulted in uniform dispersion of CNTs in dense composite compacts. Significant improvement in microhardness, nanohardness, and compressive yield strength was observed with 2 wt% CNT reinforcement in aluminum matrix composites. The Al‐CNT composites further exhibited improved wear resistance and lower friction coefficient due to strengthening and self‐lubricating effects of CNTs.     

Wetting of carbon nanotubes by aluminum oxide

Most ceramic-carbon nanotube (CNT) composite processing utilizes solid state sintering, hence the concept of wetting of CNTs by molten ceramic is absolutely new. In the present work on a plasma sprayed Al(2)O(3)-CNT nanocomposite, it is observed that molten Al(2)O(3) spreads uniformly on the CNT surface by forming a thin (～20-25?nm) ceramic layer without any cracks. The wettability of the Al(2)O(3)-CNT system is associated with the surface tension and capillary forces as captured from the evolution of microstructure. The dynamic equilibrium between melting and solidification of Al(2)O(3) was deduced from the meniscus height, curvature, contact perimeter and projection area of solidified Al(2)O(3) on the CNT surface. This interfacial phenomenon illuminates the mechanisms of microstructure evolution from Al(2)O(3)-coated CNT bridge structures to CNT mesh formation. Consequent ab?initio modeling depicted distorted iso-surface contours at the interface, suggesting partial bonding and good wettability of Al(2)O(3) on the CNT surface.     

Assessment of carbon nanotube yarns as reinforcement for composite overwrapped pressure vessels

Carbon nanotubes (CNTs) are one-dimensional nanomaterials with outstanding electrical and thermal conductivities and mechanical properties. Recent advances in CNT manufacturing have made bulk forms such as yarns, tapes and sheets available in commercial quantities to permit the evaluation of these materials for aerospace use. The high tensile properties of CNT composites can be exploited in tension-dominated applications such as composite overwrapped pressure vessels (COPVs). To investigate their utility in this application, aluminum (Al) rings were overwrapped with thermoset/CNT yarn, thermally cured under a vacuum bag, and their mechanical properties measured. Fabrication parameters such as CNT/resin ratio, tension applied during winding, and the number of CNT yarn layers were investigated to determine their effects on the mechanical performance of overwrapped Al rings. Mechanical properties of the CNT composite overwrapped Al rings (CCOARs) were measured under static and cyclic loads at room, elevated, and cryogenic temperatures to evaluate their performance relative to bare Al rings. The ultimate load carried by the composite overwrap in the CCOARs increased with increasing number of wraps. The wet winding process for the CCOAR fabrication improved load transfer compared to the dry winding process due to enhanced interfacial adhesion between the CNT yarn and the applied resin. Wet winding Al rings with CNT yarn/thermoset overwraps resulted in ∼11% increase in weight relative to the bare ring and increased the room temperature breaking load by over 200%.     

Fabrication,Microstructure and Mechanical Properties of TiC/Ti_2AlC/TiAl_3 in situ Composite

This paper described a process for synthesizing a new multiphase TiC/Ti2AlC/TiAl3 composite,in which Ti,Al4C3 and graphite powders were utilized as raw materials,and in situ spark plasma sintering-reactive sintering(SPS-RS) methods were involved.The intermediate phases of Ti3Al and TiAl were found during the reactive sintering process and the reactions for the phase’s formation were proposed.The microstructure and mechanical properties of the composites were investigated.The high-resolution transmission electron microscopy(HRTEM) image of the interface showed that no amorphous phases were detected along the grain boundary.The orientation relationships between the Ti2AlC and the TiC were shown to be(0001)Ti2AlC||(111)TiC and [110]Ti2AlC||[110]TiC.The average hardness,fracture toughness,Young’s modulus and bending strength of the composite were 15.1±0.8 GPa,4.9±0.3 MPa·m 1/2,261±13 GPa and 776±18 MPa,respectively.The toughening mechanism was also discussed.     

放电等离子烧结Ti-Al系金属间化合物

用机械合金化法(MA)制备了Ti-45% Al纳米晶合金粉末,并对其进行放电等离子烧结(SPS),烧结时间仅为5min.用D-maxIIA型X射线衍射仪、JEM-2000EX型透射电子显微镜对粉末和烧结块体的微观组织及机械性能进行了研究.研究表明:Ti和Al的粉末随着球磨时间的延长,粉末有明显的细化趋势,球磨5h即有非晶产生,球磨20h后得到接近完全非晶相;采用SPS烧结技术,在1200℃下能够制备出较高硬度的TiAl金属间化合物块体材料.     

机械合金化-放电等离子烧结Al2Cu颗粒增强Al基复合材料的制备

以Al粉和Cu粉为原料,采用机械合金化(MA)和放电等离子烧结(SPS)工艺,原位合成了致密的Al₂Cu/Al块体复合材料,着重研究了MA过程中粉末的形貌、尺寸和物相结构的变化以及SPS后复合材料的微观组织和力学性能。结果表明: 在MA过程中,随着MA时间延长,部分Cu原子逐渐固溶于Al原子晶格中,形成均匀过饱和的固溶体Al(Cu);在SPS过程中,Cu从过饱和固溶体中析出并与Al反应形成Al₂Cu颗粒,且弥散分布于Al基体中,形成Al₂Cu/Al复合材料;Al₂Cu/Al复合材料的致密度高达98.7%,室温下的压缩断裂强度为611.3 MPa,延伸率为9.6%,具有良好的力学性能。     

Properties of polypropylene composites containing aluminum/multi-walled carbon nanotubes

Polypropylene/aluminum–multi-walled carbon nanotube (PP/Al–CNT) composites were prepared by a twin-screw extruder. The morphology indicates that the CNTs are well embedded or implanted within Al-flakes rather than attached on the surface. During preparation of composites, the CNTs came apart from Al–CNT so that free CNTs as well as Al–CNT were observed in PP/Al–CNT composite. The crystallization temperatures of PP/CNT and PP/Al–CNT composites were increased from 111 °C for PP to 127 °C for the composites. The decomposition temperature increased by 55 °C for PP/CNT composite and 75 °C for PP/Al–CNT composite. The PP/Al–CNT composite showed higher thermal conductivity than PP/CNT and PP/Al-flake composites with increasing filler content. PP/Al–CNT composites showed the viscosity values between PP/CNT and PP/Al-flake composites. PP/Al–CNT composite showed higher tensile modulus and lower tensile strength with increasing filler content compared to PP/CNT and PP/Al-flake composites.     

Microstructures and tensile behavior of carbon nanotube reinforced Cu matrix nanocomposites

Carbon nanotubes (CNTs) have been considered as an ideal reinforcement to improve the mechanical performance of monolithic materials. However, the CNT/metal nanocomposites have shown lower strength than expected. In this study, the CNT reinforced Cu matrix nanocomposites were fabricated by spark plasma sintering (SPS) of high energy ball-milled nano-sized Cu powders with multi-wall CNTs, and followed by cold rolling process. The microstructure of CNT/Cu nanocomposites consists of two regions including CNT/Cu composite region, where most CNTs are distributed, and CNT free Cu matrix region. The stress–strain curves of CNT/Cu nanocomposites show a two-step yielding behavior, which is caused from the microstructural characteristics consisting of two regions and the load transfer between these regions. The CNT/Cu nanocomposites show a tensile strength of 281 MPa, which is approximately 1.6 times higher than that of monolithic Cu. It is confirmed that the key issue to enhance the strength of CNT/metal nanocomposite is homogeneous distribution of CNTs.     

Microstructure and mechanical properties of CNT/Ag nanocomposites fabricated by spark plasma sintering

Carbon nanotube/silver (CNT/Ag) nanocomposites include CNT volume fraction up to 10?vol.% were prepared by chemical reduction in solution followed by spark plasma sintering. Multiwalled CNTs underwent surface modifications by acid treatments, the Fourier transform infrared spectroscopy data indicated several functional groups loaded on the CNT surface by acid functionalisation. The acid-treated CNTs were sensitised and activated. Silver was deposited on the surface of the activated CNTs by chemical reduction of alkaline silver nitrate solution at room temperature. The microstructures of the prepared CNT/Ag nanocomposite powders were investigated by high-resolution scanning electron microscopy (HRSEM), transmission electron microscopy and X-ray powder diffraction analysis. The results indicated that the produced CNT/Ag nanocomposite powders have coated type morphology. The produced CNT/Ag nanocomposite powders were sintered by spark plasma sintering. It was observed from the microstructure investigations of the sintered materials by HRSEM that the CNTs were distributed in the silver matrix with good homogeneity. The hardness and the tensile properties of the produced CNT/Ag nanocomposites were measured. By increasing the volume fraction of CNTs in the silver matrix, the hardness values increased but the elongation values of the prepared CNT/Ag nanocomposites decreased. In addition, the tensile strength was increased by increasing the CNTs volume fraction up to 7.5?vol.%, but the sample composed of 10?vol.% CNT/Ag was fractured before yielding.     

Mechanical characterization of copper coated carbon nanotubes reinforced aluminum matrix composites

In this investigation, carbon nanotube (CNT) reinforced aluminum composites were prepared by the molecular-level mixing process using copper coated CNTs. The mixing of CNTs was accomplished by ultrasonic mixing and ball milling. Electroless Cu-coated CNTs were used to enhance the interfacial bonding between CNTs and aluminum. Scanning electron microscope analysis revealed the homogenous dispersion of Cu-coated CNTs in the composite samples compared with the uncoated CNTs. The samples were pressureless sintered under vacuum followed by hot rolling to promote the uniform microstructure and dispersion of CNTs. In 1.0 wt.% uncoated and Cu-coated CNT/Al composites, compared to pure Al, the microhardness increased by 44% and 103%, respectively. As compared to the pure Al, for 1.0 wt.% uncoated CNT/Al composite, increase in yield strength and ultimate tensile strength was estimated about 58% and 62%, respectively. However, in case of 1.0 wt.% Cu-coated CNT/Al composite, yield strength and ultimate tensile strength were increased significantly about 121% and 107%, respectively.     

Synthesis and characterization of vertically aligned carbon nanotube forest for solid state fiber spinning

Continuous carbon nanotubes (CNT) fibers were directly spun from a vertically aligned CNT forest grown by a plasma-enhanced chemical vapor deposition (PECVD) process. The correlation of the CNT structure with Fe catalyst coarsening, reaction time, and the CNTs bundling phenomenon was investigated. We controlled the diameters and walls of the CNTs and minimized the amorphous carbon deposition on the CNTs for favorable bundling and spinning of the CNT fibers. The CNT fibers were fabricated with an as-grown vertically aligned CNT forest by a PECVD process using nanocatalyst an Al2O3 buffer layer, followed by a dry spinning process. Well-aligned CNT fibers were successfully manufactured using a dry spinning process and a surface tension-based densification process by ethanol. The mechanical properties were characterized for the CNT fibers spun from different lengths of a vertically aligned CNT forest. Highly oriented CNT fibers from the dry spinning process were characterized with high strength, high modulus, and high electrical as well as thermal conductivities for possible application as ultralight, highly strong structural materials. Examples of structural materials include space elevator cables, artificial muscle, and armor material, while multifunctional materials include E-textile, touch panels, biosensors, and super capacitors.     

Role of powder treatment and carbon nanotube dispersion in the fracture toughening of plasma-sprayed aluminum oxide-carbon nanotube nanocomposite

Al2O3 ceramic reinforced with 4-wt% multiwalled carbon nanotube (CNT) is plasma sprayed for improving the fracture toughness of the nanocomposite coating. Two different methodologies of CNT addition have been adopted in the powder feedstock to assist CNT dispersion in the nano-Al2O3 matrix. First, spray-dried nano-Al2O3 agglomerates are blended with 4 wt% CNT as powder-feedstock, which is subsequently plasma sprayed resulting in the fracture toughness improvement of 19.9%. Secondly, spray dried composite nano-Al2O3 and 4 wt% CNT powder was used as feedstock for attaining improved dispersion of CNTs. Plasma sprayed coating of composite spray dried powder resulted in increase of 42.9% in the fracture toughness. Coating synthesized from the blended powder displayed impact alignment of CNTs along splat interface, and CNTs chain loop structure anchoring the fused Al2O3 melt whereas coating synthesized from composite spray dried powder evinced anchoring of CNTs in the solid state sintered region and CNT mesh formation. Enhanced fracture toughness is attributed to significance of CNT dispersion.     

球磨工艺对原位合成碳纳米管增强铝基复合材料微观组织和力学性能的影响

将原位化学气相沉积法合成的碳纳米管(CNTs)与铝的复合粉末进行球磨混合,进而粉末冶金制备CNTs/Al复合材料,研究球磨工艺对复合材料的微观组织和力学性能的影响。结果表明:球磨过程中不添加过程控制剂所得到的复合材料力学性能优异;随着球磨时间的增加,CNTs逐步分散嵌入铝基体内部,复合材料的组织也变得更加致密均匀。CNTs/Al复合材料的硬度和抗拉强度均随球磨时间的延长持续增加,但是伸长率先增后减。经90min球磨的CNTs/Al复合材料展现了强韧兼备的特点,其硬度和抗拉强度较原始纯铝提高了1.4倍和1.7倍,并且具有17.9%的高伸长率。     

放电等离子烧结制备高导热SiC_P/Al电子封装材料

为了满足电子封装材料越来越高的性能要求,采用放电等离子烧结(SPS)工艺制备了SiCP/Al复合材料。研究了烧结温度和保温时间等工艺条件对SiCP/Al复合材料组织形貌和性能的影响。结果表明:采用SPS烧结,温度为700℃、保温时间为5 min时,所制备的70 vol%SiCP/Al复合材料热导率达到195.5 W(m.K)-1,与传统15%W-Cu合金相当,是Kovar合金的10倍,但密度小,仅为3.0 g.cm-3;其热膨胀系数为6.8×10-6K-1,与基板材料热膨胀系数接近;抗弯强度为410 MPa,抗拉强度为190 MPa,达到了电子封装材料对热学性能和力学性能的要求。     

Al/CNT nanocomposite fabrication on the different property of raw material using a planetary ball mill

In recent years, significant research has been focused on the development of carbon nanotube (CNT) reinforced aluminum nanocomposites, which are quickly emerging because of their lightweight, high strength and other mechanical properties. The potential applications of these composites include the automotive and aerospace industries. In this study, powder metallurgy techniques are employed to fabricate aluminum (Al)/CNT nanocomposites with different raw material properties with optimized conditions. We successfully fabricated three different samples, including un-milled Al, un-milled Al with CNT and milled Al with CNT nanocomposites, in the presence of additional CNTs with various experimental conditions using a planetary ball mill. Scanning electron microscopy and field emission scanning electron microscopy are used to evaluate the particle morphology and CNT dispersion. The CNTs are well dispersed on the surface of the fabricated milled Al with CNT nanocomposites than un-milled Al with CNT nanocomposites for milling. The fabricated Al/CNT nanocomposites are processed by a compacting, sintering and rolling process. Vickers hardness measurements are used to characterize the mechanical properties. The hardness of the Al/CNT nanocomposites are improved milled Al with CNT nanocomposite compared other fabricated composites.     

放电等离子烧结制备块体非晶合金研究进展

非晶合金又称“金属玻璃”,是由于超快速冷却凝固导致无法有序排列结晶,从而得到的一种长程无序结构。这种非晶合金与存在晶界和位错的普通合金相比,具有更加优异的力学及物化性能。由于粉末状或条状非晶合金在尺寸和性能等方面的限制,因而大尺寸、优异力学性能及软磁性能卓越的块体非晶合金的制备受到了大量关注与探究。放电等离子烧结技术以温度低、效率高、时间短及冷却速率快等优点,被认为是一种具有广阔发展前景的制备方法。对Fe基、Zr基、Al基及Ti基本身的特点,以及通过放电等离子烧结技术制备不同体系块体非晶合金的物理及化学性能的研究进行了较为全面的综述。概述了放电等离子烧结技术的原理及在制备块体非晶合金方面的优势;分析了放电等离子烧结技术和制备的块体非晶合金材料存在的问题,以及采用该技术制备块体非晶合金的发展前景。重点介绍了在采用该制备不同体系的块体非晶合金时,如何通过改变放电等离子烧结参数,或通过再加工、本身粉末添加元素等方法获得大尺寸、优异性能的块体非晶合金。