Microstructural and mechanical properties of Al-Mg/Al2O3 nanocomposite prepared by mechanical alloying

The effect of milling time on the microstructure and mechanical properties of Al and Al-10 wt.% Mg matrix nanocomposites reinforced with 5 wt.% Al₂O₃ during mechanical alloying was investigated. Steady-state situation was occurred in Al-10Mg/5Al₂O₃ nanocomposite after 20 h, due to solution of Mg into Al matrix, while the situation was not observed in Al/5Al₂O₃ nanocomposite at the same time. For the binary Al-Mg matrix, after 10 h, the predominant phase was an Al-Mg solid solution with an average crystallite size 34 nm. Up to 10 h, the lattice strain increased to about 0.4 and 0.66% for Al and Al-Mg matrix, respectively. The increasing of lattice parameter due to dissolution of Mg atom into Al lattice during milling was significant. By milling for 10 h the dramatic increase in microhardness (155 HV) for Al-Mg matrix nanocomposite was caused by grain refinement and solid solution formation. From 10 to 20 h, slower rate of increasing in microhardness may be attributed to the completion of alloying process, and dynamic and static recovery of powders.     

Effect of reinforcement NbC phase on the mechanical properties of Al2O3-NbC nanocomposites obtained by spark plasma sintering

The sintering behavior of Al₂O₃-NbC nanocomposites fabricated via conventional and spark plasma sintering (SPS) was investigated. The nanometric powders of NbC were prepared by reactive high-energy milling, deagglomerated, leached with acid, added to the Al₂O₃ matrix in the proportion of 5 vol% and dried under airflow. Then, the nanocomposite powders were densified at different temperatures, 1450–1600 °C. Effect of sintering temperature on the microstructure and mechanical properties such as hardness, toughness and bending strength were analyzed. The Al₂O₃-NbC nanocomposites obtained by SPS show full density and maximum hardness value > 25 GPa and bending strength of 532 MPa at 1500 °C. Microstructure observations indicate that NbC nanoparticles are dispersed homogeneously within Al₂O₃ matrix and limit their grain growth. Scanning electron microscopy examination of the fracture surfaces of dense samples obtained at 1600 °C by SPS revealed partial melting of the particle surfaces due to the discharge effect.     

Process−microstructure−properties relationship in Al−CNTs−Al2O3 nanocomposites manufactured by hybrid powder metallurgy and microwave sintering process

Al−2CNTs−xAl₂O₃ nanocomposites were manufactured by a hybrid powder metallurgy and microwave sintering process. The correlation between process-induced microstructural features and the material properties including physical and mechanical properties as well as ultrasonic parameters was measured. It was found that physical properties including densification and physical dimensional changes were closely associated with the morphology and particle size of nanocomposite powders. The maximum density was obtained by extensive particle refinement at milling time longer than 8 h and Al₂O₃ content of 10 wt.%. Mechanical properties were controlled by Al₂O₃ content, dispersion of nano reinforcements and grain size. The optimum hardness and strength properties were achieved through incorporation of 10 wt.% Al₂O₃ and homogenous dispersion of CNTs and Al₂O₃ nanoparticles (NPs) at 12 h of milling which resulted in the formation of high density of dislocations and extensive grain size refinement. Also both longitudinal and shear velocities and attenuation increase linearly by increasing Al₂O₃ content and milling time. The variation of ultrasonic velocity and attenuation was attributed to the degree of dispersion of CNTs and Al₂O₃ and also less inter-particle spacing in the matrix. The larger Al₂O₃ content and more homogenous dispersion of CNTs and Al₂O₃ NPs at longer milling time exerted higher velocity and attenuation of ultrasonic wave.     

Fabrication of AA2024−TiO2 nanocomposites through stir casting process

Given the nonuse of TiO₂ nanoparticles as the reinforcement of AA2024 alloy in fabricating composites by ex-situ casting methods, it was decided to process the AA2024−xTiO_2(np) (x=0, 0.5 and 1 vol.%) nanocomposites by employing the stir casting method. The structural properties of the produced samples were then investigated by optical microscopy and scanning electron microscopy; their mechanical properties were also addressed by hardness and tensile tests. The results showed that adding 1 vol.% TiO₂ nanoparticles reduced the grain size and dendrite arm spacing by about 66% and 31%, respectively. Also, hardness, ultimate tensile strength, yield strength, and elongation of AA2024− 1vol.%TiO_2(np) composite were increased by about 25%, 28%, 4% and 163%, respectively, as compared to those of the monolithic component. The agglomerations of nanoparticles in the structure of nanocomposites were found to be a factor weakening the strength against the strengthening mechanisms. Some agglomerations of nanoparticles in the matrix were detected on the fractured surfaces of the tension test specimens.     

Microstructure and morphological study of ball-milled metal matrix nanocomposites

Due to the difficulty of preparation and beneficial properties achievable, copper and iron matrix nanocomposites are materials for which fabrication via the powder metallurgy route is attracting increasing research interest. The presence of ceramic nanoparticles in their matrix can lead to considerable changes in the microstructure and morphology. The effects of the type of metallic matrix and ceramic nanoparticle on the distribution of nano reinforcements and the morphology of ball-milled composite powders were evaluated in this study. For this purpose, 25 wt % of Al₂O₃ and SiC nanoparticles were separately ball-milled in the presence of iron and copper metals. The SEM, FESEM, and XRD results indicated that as-received nanoparticles, which were agglomerated before milling, were partially separated and embedded in the matrix of both the metals after the initial stages of ball milling, while prolonged milling was not found to further affect the distribution of nanoparticles. It was also observed that the Al₂O₃ phase was not thermodynamically stable during ball milling with copper powders. Finally, it was found that the presence of nanoparticles considerably reduce the average size of metallic powder particles.     

Magnetic multiresonance behavior of Fe@Al2O3 nanoembedments and microstructural evolution during mechanosynthesis

The embedding of metal nanoparticles into an insulating ceramic matrix can provide encapsulation and prevent their oxidation and agglomeration. A nanoembedment powder with the Fe nanoparticles embedded into Al₂O₃ matrix is prepared by high-energy ball milling. Starting from the highly exothermic reactant mixture of magnetite and aluminum, Fe nanoparticles were in situ formed in Al₂O₃ matrix by mechanochemical reaction. It is found that a post-reaction milling significantly narrows the size distribution of Fe nanoparticles. The mechanism for the two-stage milling process was proposed. The microwave permeability of nanoembedments exhibited a multiresonance behavior, which was the evidence for monodispersed Fe nanoparticles. The Fe@Al₂O₃ nanoembedments are potential candidates as microwave absorber and left-handed materials.     

Influence of ultrasonication on the mechanical properties of Cu/Al2O3 nanocomposite thin films during electrocodeposition

To overcome the poor mechanical properties of pure Cu thin films, we performed electrocodeposition to make nanocomposite thin films by incorporating inert Al₂O₃ nanoparticles (50 nm and 300 nm in diameter). In addition, to reduce agglomeration due to their high surface energy, we used ultrasonication during the electrocodeposition. In this paper, we examined the effects of the ultrasonication on the mechanical properties of nanocomposite films with different ultrasonic energy density up to 225 W/cm². Ultrasonication during electrocodeposition efficiently reduced the agglomeration of nanoparticles and reduced the grain size of the Cu matrix. Smaller nanoparticles were more efficiently de-agglomerated by ultrasonication, which resulted in more enhanced mechanical properties in the 50 nm Al₂O₃ nanoparticle-enhanced specimens. Although the addition of nanoparticles in the Cu matrices significantly increased the hardness of the specimens, as observed in nanoindentation tests, we did not observe such an increase in tensile tests. Reducing the grain size by ultrasonication seems to be an important parameter in enhancing the overall mechanical properties of nanocomposites. Ultrasonication provided a significant increase in all mechanical properties, including elastic modulus, yield stress, ultimate tensile stress, and elongation, of all controlled Cu films.     

Consolidation of Al2O3/Al Nanocomposite Powder by Cold Spray

While the improvement in mechanical properties of nanocomposites makes them attractive materials for structural applications, their processing still presents significant challenges. In this article, cold spray was used to consolidate milled Al and Al₂O₃/Al nanocomposite powders as well as the initial unmilled and unreinforced Al powder. The microstructure and nanohardness of the feedstock powders as well as those of the resulting coatings were compared. The results show that the large increase in hardness of the Al powder after mechanical milling is preserved after cold spraying. Good quality coating with low porosity is obtained from milled Al. However, the addition of Al₂O₃ to the Al powder during milling decreases the powder and coating nanohardness. This lower hardness is attributed to non-optimized milling parameters leading to cracked particles with insufficient Al₂O₃ embedding in Al. The coating produced from the milled Al₂O₃/Al mixture also showed lower particle cohesion and higher amount of porosity.     

Electrochemical and interfacial properties of (PEO)<Subscript>10</Subscript>LiCF<Subscript>3</Subscript>SO<Subscript>3</Subscript>−Al<Subscript>2</Subscript>O<Subscript>3</Subscript> nanocomposite polymer electrolytes using ball milling

Electrochemical and interfacial properties of (PEO)₁₀LiCF₃SO₃−Al₂O₃ composite polymer electrolytes (CPEs) prepared by either ball milling or stirring are reported. Ball milling was introduced into a slurry preparative technique utilizing PEO, lithium salt and Al₂O₃ powder ranging from 5 to 15 wt.%. The ionic conductivity was increased by ball milling over a range of temperatures. In particular, a significant increase at low temperature below the melting point of crystalline PEO was observed. Interfacial stability between lithium electrode and CPE was significantly improved by the addition of alumina as well as by ball milling. The electrochemical stability window produced by (PEO)₁₀LiCF₃SO₃−Al₂O₃ ball milling was higher than that of stirring, which was about 4.4 V. Charge/discharge performance of Li/CPE/S cells with (PEO)₁₀LiCF₃SO₃−Al₂O₃-12 hr ball milling was superior to that of a pristine polymer electrolyte due to the low interface resistance and high ionic conductivity.     

Enhanced Seebeck coefficient by energy filtering in Bi-Sb-Te based composites with dispersed Y2O3 nanoparticles

The incorporation of ceramic nanoparticles in the bulk thermoelectric matrix is one of the new strategies to boost the Seebeck coefficient. In this research, different weight percentages of Y₂O₃ (2, 4, and 6) nanoparticles (NPs) were incorporated into the pre-alloyed BiSbTe powder for making nanocomposites (NCs) by mechanical milling. The resultant NCs powders were subsequently consolidation by spark plasma sintering (SPS) at 450 °C. The existence of Y₂O₃ nano-inclusions was confirmed by x-ray diffraction and TEM-SAED analysis. The hardness of the nanocomposites was significantly improved (>49%) compared to that of pure BiSbTe, and this was attributed to grain-boundary hardening and to a dispersion strengthening mechanism. The electrical conductivity decreased while the Seebeck coefficient significantly improved (45%) at room temperature for the NCs to which 2 wt% Y₂O₃ was added. This was due to the scattering of carriers through the energy filtering effect. The electronic component of the thermal conductivity greatly contributed to the reduction of total thermal conductivity (22%) in BiSbTe NCs to which 6 wt% Y₂O₃ was added. A peak ZT of 1.24 was achieved for BiSbTe/(2 wt%) Y₂O₃ NCs due to reduction in their thermal conductivity and improved Seebeck coefficient values.     

Ag-Cu-Sn-Ti活性钎焊Gr/2024Al复合材料与TC4钛合金

采用自制的AgCuSnTi钎料对发汗材料Gr/2024Al复合材料和TC4钛合金进行钎焊,对焊后接头界面组织及力学性能进行了分析.结果表明,接头典型界面组织为Gr/2024Al/Ti₃AlC₂/Ag₂Al+Ag₃Sn+Al₂Cu+Al₅CuTi₂/Al₅CuTi₂+Ag₃Sn/TC4.钎焊时,活性元素Ti与Gr/2024Al复合材料的石墨基体发生活性反应,实现了TC4与Gr/2024Al复合材料的低温连接,保证了复合材料的力学性能及发汗功能.随钎焊温度升高及保温时间延长,钎缝组织中弥散分布的Al₅CuTi₂化合物聚集长大成块状,使接头性能下降.当钎焊温度为680℃,保温时间为10min时接头抗剪强度达到最大值17MPa,其为Gr/2024Al复合材料母材强度的70%.     

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.     

Characterization and Formation Mechanism of Ni3Si–Al2O3 Nanocomposite Prepared by Mechanochemical Reduction Method

In this present work, Ni₃Si–Al₂O₃ nanocomposite powders were synthesized by mechanical milling using NiO, Si and Al as raw materials. The phase transformation, formation mechanism and microstructure evolution of the powders during mechanical milling were investigated by X-ray diffraction (XRD), differential thermal analysis (DTA), scanning electron microscopy (SEM), transition electron microscopy (TEM) and microhardness measurements. Results showed that the Ni₃Si, Al₂O₃ and Ni₃₁Si₁₂ phases formed after 5 h of milling with a rapid mechanically induced self-propagating synthesis mode. The average grain size and internal strain of Ni₃Si and Al₂O₃ after 30 h of milling were (16.8 nm, 1.27%) and (19.6 nm, 0.94%), respectively. The maximum microhardness value of 813 HV was obtained in the 30 h milled powder. The relationship between the hardness and grain size of the powders satisfies the Hall–Petch relationship. Ni₃Si–Al₂O₃ nanocomposite powders are very stable during heating at 950 °C. By annealing of the milled powders leads to grain growth, internal strain and microhardness of Ni₃Si powder decrease and transformation of disordered structure to an ordered state. A long-range ordering parameter (LRO) of 0.97 for the ordered Ni₃Si can be achieved after annealing at 950 °C for 2 h.

     

Influence of Al2O3 nanoparticles on solubility extension of Cr in Cu by mechanical alloying

In this study, the effect of the presence of Al₂O₃ nanoparticles during mechanical alloying on the extension of Cr solid solubility in Cu was investigated. The lattice parameter, dislocation density and crystallite size were evaluated by the X-ray diffraction technique. Also, the microstructure was characterized by scanning electron microscopy and transmission electron microscopy. The final product was a nanocrystalline and supersaturated Cu–Cr solid solution with a mean crystallite size ranging from 8 to 19 nm depending on the composition. The Gibbs free energy changes in these systems due to the dislocation density and crystallite size variations during milling were calculated. It was found that the presence of Al₂O₃ nanoparticles was beneficial to the process, and this was particularly related to its significant contribution to the increase of strain part of Gibbs free energy changes.     

Interfacial investigation,mechanical performance and thermal permanence of the inductively hot-pressed alumina ceramic hybrid nanocomposites reinforced by silicon carbide and multilayer graphene

Hybrid alumina (Al₂O₃) ceramic nanocomposites containing 3 wt% silicon carbide nanoparticles (SiCnp) and 0.5 wt% multilayer graphene (MLG) were consolidated to near theoretical density (99%) by an inductive hot-pressing (IHP) technology. The enhanced fracture toughness and hardness by 97% and 15% respectively, for the hybrid nanocomposites over the reference Al₂O₃ were attributed to the higher densification, uniformly dispersed reinforcing constituents within the base matrix, toughening mechanisms of crack-deflection by the 0D-SiCnp and grain-anchoring as well as crack-bridging induced by the 2D-MLG. Thermal investigations of the hybrid nanocomposite verified the occurrence of a chemical reaction at the MLG/Al₂O₃ interface and thermal diffusion at SiCnp/Al₂O₃ interface during inductive hot-pressing. The bonding characteristics and interfacial microstructure were appraised by infra-red spectroscopy and high-resolution TEM microscope. Furthermore, the thermal stability in different gaseous environments and the ballistic performance of the hybrid nanocomposites were characterized and discussed. The produced hybrid nanocomposites may be suitable for high-temperature aerospace structural parts and may have applications in high-velocity impact technology.     

Reinforcing capability of multiwall carbon nanotubes in alumina ceramic hybrid nanocomposites containing zirconium oxide nanoparticles

In this study, we investigate the reinforcing capability of multiwall carbon nanotubes (mwCNT) in alumina (Al₂O₃) ceramic hybrid nanocomposites containing zirconium oxide nanoparticles (ZrO₂np). For this purpose, highly dense hybrid nanocomposites containing well-dispersed ZrO₂np (8 vol%) and mwCNT (4 vol%) were fabricated by the hot-pressing method. The resulting hybrid nanocomposite exhibited a ten-fold finer microstructure and 116% enhanced fracture toughness as well as 12% greater hardness over the benchmarked monolithic Al₂O₃. The superior mechanical performance of the hybrid nanocomposite was attributed to the synergistic role of ZrO₂np and mwCNT in refining the matrix microstructure and inducing unique toughening mechanisms of micro-cracking by ZrO₂np and pull-out as well as crack-bridging by mwCNT. Qualitative and quantitative approaches were utilized to assess the individual and collective role of the reinforcing constituents in enhancing the performance of hybrid nanocomposite. The qualitative analysis by electron microscopes demonstrated strong interfacial adhesion of both reinforcing constituents with the based Al₂O₃ matrix. Furthermore, the quantitative analysis verified that the enhanced mwCNT/Al₂O₃ interfacial shear strength is caused by the intricate physical arrangement of the mwCNT within the matrix grains besides their chemical bonding at the interface. The role of fine-grained microstructure in establishing idiosyncratic mwCNT interlocking with the Al₂O₃ matrix grains was meticulously investigated. Moreover, the influence of mwCNT/matrix interlocking on the mwCNT reinforcing ability and toughening mechanisms efficiency in the hybrid nanocomposite is discussed.     

Effect of weight percentage and particle size of B4C reinforcement on physical and mechanical properties of powder metallurgy Al2024-B4C composites

In this study, Al2024-B₄C composites containing 0, 5, 10 and 20 wt% of B₄C particles with two different particle sizes (d₅₀=49 μm and d₅₀=5 μm) as reinforcement material were produced by a mechanical alloying method. Two new particle distribution models based on the size of reinforcement materials was developed. The microstructure of the Al2024-B₄C composites was investigated using a scanning electron microscope. The effects of reinforcement particle size and weight percentage (wt%) on the physical and mechanical properties of the Al2024-B₄C composites were determined by measuring the density, hardness and tensile strength values. The results showed that more homogenous dispersion of B₄C powders was obtained in the Al2024 matrix using the mechanical alloying technique according to the conventional powder metallurgy method. Measurement of the density and hardness properties of the composites showed that density values decreased and hardness values increased with an increase in the weight fraction of reinforcement. Moreover, it was found that the effect of reinforcement size and reinforcement content (wt%) on the homogeneous distribution of B₄C particles is as important as the effect of milling time.     

Characterization and formation mechanism of nanocrystalline (Fe,Ti)3Al intermetallic compound prepared by mechanical alloying

The nanocrystalline (Fe,Ti)₃Al intermetallic compound was synthesized by mechanical alloying (MA) of elemental powder with composition Fe₅₀Al₂₅Ti₂₅. The structural changes of powder particles during mechanical alloying were studied by X-ray diffractometry and microhardness measurements. Morphology and cross-sectional microstructure of powder particles were characterized by scanning electron microscopy. It was found that a Fe/Al/Ti layered structure was formed at the early stages of milling followed by the formation of Fe(Ti,Al) solid solution. This structure transformed to (Fe,Ti)₃Al intermetallic compound at longer milling times. Upon heat treatment of (Fe,Ti)₃Al phase the degree of DO₃ ordering was increased. The (Fe,Ti)₃Al compound exhibited high microhardness value of about 1050 Hv.     

Fabrication of Al matrix composite reinforced with submicrometer-sized Al<Subscript>2</Subscript>O<Subscript>3</Subscript> particles formed by combustion reaction between HEMM Al and V<Subscript>2</Subscript>O<Subscript>5</Subscript> composite particles during sintering

To fabricate an Al-V matrix composite reinforced with submicron-sized Al₂O₃ and Al_xV_y (Al₃V, Al₁₀V) phases, high energy mechanical milling (HEMM) and sintering were employed. By increasing the milling time, the size of mechanically milled powder was significantly reduced. In this study, the average powder size of 59 μm for Al, and 178 μm for V₂O₅ decreased with the formation of a new product, Al-Al₂O₃-Al_xV_y, with a size range from 1.3 μm to 2.6 μm formed by the in-situ combustion reaction during sintering of HEM milled Al and V₂O₅ composite powders. The in-situ reaction between Al and V₂O₅ during the HEMM and sintering transformed the Al₂O₃ and Al_xV_y (Al₃V, Al₁₀V) phases. Most of the reduced V reacted with excess the Al to form Al_xV_y (Al₃V, Al₁₀V) with very little V dissolved into Al matrix. By increasing the milling time and weight percentage of V₂O₅, the hardness of the Al-Al₂O₃-Al_xV_y composite sintered at 1173 K increased. The composite fabricated with the HEMM Al-20wt.%V₂O₅ composite powder and sintering at 1173 K for 2 h had the highest hardness.     

Al2O3-nanodiamond composite coatings with high durability and hydrophobicity prepared by aerosol deposition

We attempted the room-temperature fabrication of Al₂O₃-based nanodiamond (ND) composite coating films on glass substrates by an aerosol deposition (AD) process to improve the anti-scratch and anti-smudge properties of the films. Submicron Al₂O₃ powder capable of fabricating transparent hard coating films was used as a base material for the starting powders, and ND treated by 1H,1H,2H,2H-perfluorooctyltriethoxysilane (PFOTES) was added to the Al₂O₃ to increase the hydrophobicity and anti-wear properties. The ND powder treated by PFOTES was mixed with the Al₂O₃ powder by ball milling to ratios of 0.01 wt.%, 0.03 wt.%, and 0.05 wt.% ND. The water contact angle (CA) of the Al₂O₃-ND composite coating films was increased as the ND ratio increased, and the maximum water CA among all the films was 110°. In contrast to the water CA, the Al₂O₃-ND composite coating films showed low transmittance values of below 50% at a wavelength of 550 nm due to the strong agglomeration of ND. To prevent the agglomeration of ND, the starting powders were mixed by attrition milling. As a result, Al₂O₃-ND composite coating films were produced that showed high transmittance values of close to 80%, even though the starting powder included 1.0 wt.% ND. In addition, the Al₂O₃-ND composite coating films had a high water CA of 109° and superior anti-wear properties compared to those of glass substrates.