Microstructural Design of Silicon Nitride with Improved Fracture Toughness: II, Effects of Yttria and Alumina Additives

Significant improvements in the fracture resistance of self-reinforced silicon nitride ceramics have been obtained by tailoring the chemistry of the intergranular amorphous phase. First, the overall microstructure of the material was controlled by incorporation of a fixed amount of elongated ß-Si₃N₄ seeds into the starting powder to regulate the size and fraction of the large reinforcing grains. With controlled microstructures, the interfacial debond strength between the reinforcement and the intergranular glass was optimized by varying the yttria-to-alumina ratio in the sintering additives. It was found that the steady-state fracture toughness value of these silicon nitrides increased with the Y:Al ratio of the oxide additives. The increased toughness was accompanied by a steeply rising R -curve and extensive interfacial debonding between the elongated ß-Si₃N₄ grains and the intergranular glassy phase. Microstructural analyses indicate that the different fracture behavior is related to the Al (and O) content in the ß´-SiAlON growth layer formed on the elongated ß-Si₃N₄ grains during densification. The results imply that the interfacial bond strength is a function of the extent of Al and Si bonding with N and O in the adjoining phases with an abrupt structural/chemical interface achieved by reducing the Al concentration in both the intergranular phase and the ß´-SiAlON growth layer. Analytical modeling revealed that the residual thermal expansion mismatch stress is not a dominant influence on the interfacial fracture behavior when a distinct ß´-SiAlON growth layer forms. It is concluded that the fracture resistance of self-reinforced silicon nitrides can be improved by optimizing the sintering additives employed.     

Performance of non-destructive evaluation by diffracted SH ultrasonic waves in predicting degree of fatigue in cyclic bending of ferritic steel

The degree of fatigue in ferritic wrought steel during cyclic bending was determined by analysis of diffracted SH ultrasonic waves with the aid of multiple regression analysis. As the degree of fatigue increases, accompanied by residual stress, the incident waves curve to the interior region with positive stress field owing to the acoustoelastic effect. As a result, the propagation time of the launched waves lengthens, leading to a modulation of the received waveform. Multiple regression analysis for the waveform modulation produces a reliable estimation, with correlation coefficient of 0.948, for the degree of fatigue.     

Starting method of a superconducting generator in a combined‐cycle power plant

In the combined‐cycle power plant generators are started by using the igniting arrangement up to the ignition rotational speed of the gas turbine. On the other hand, in the case of using the superconducting generator, it is difficult to apply the igniting arrangement used to generate electricity on the combined cycle for the structure as is. We examined the induction motor starting method for the superconducting generator by using the 70‐MW‐class quick‐response excitation superconducting model generator and the VVVF power supply. From the examination, we confirmed the ability to raise the rotational speed from 6 to 360 rpm. Moreover, it was found to be able to start 200‐MW‐class superconducting generators by the induction motor starting method with the analysis. © 2007 Wiley Periodicals, Inc. Electr Eng Jpn, 160(2): 30– 38, 2007; Published online in Wiley InterScience ( www.interscience. wiley.com ). DOI 10.1002/eej.20283     

Study on sustainable redevelopment of a densely built-up area in Tokyo by introducing a distributed local energy supply system

“Distributed local energy systems” had been expected to rationalize the supply of energy to built-up areas, but until now very little research has been performed to estimate the effect of their application to actual cities. In this research, therefore, a future vision for the year 2030 in the Sancha Area (SANCHA VISION 2030), a typical densely built-up area in Tokyo, has been elaborated including a simulation to estimate benefits from the application of distributed energy systems in terms of reduced energy consumption and CO₂ emissions as well as mitigation of the heat-island phenomenon. As a result, it was demonstrated that a “distributed local energy system”, which provides a district with both electrical power and heat through an integrated distribution system, may contribute to a considerable improvement in energy efficiency for those areas. In addition, it may also provide other benefits, including enhancement of living amenity and urban security in times of emergency.     

The fabrication and thermomechanical behavior of Al and Ti SMA composites

Two kinds of composites—Ti-Ni shape-memory alloy (SMA) fiber-reinforced 6061 aluminum matrix composite and Ti-Pd(Ni) SMA-reinforced titanium-matrix composite—were fabricated by various processing methods and their microstructure and thermomechanical behavior were investigated. In both sets of composites, an increase in yield stress at high temperature was mainly caused by residual compressive stress created in the matrix in association with shape-memory effects of the embedded SMAs. For more information, contact Kiyoshi Mizuuchi, Osaka Municipal Technical Research Institute, Osaka 536-8553, Japan; e-mail: mizuuchi@omtri.city.osaka.jp.     

Sinterability of various high-purity magnesium oxide powders

The sinterability of high-purity MgO powders with different production histories was investigated to make clear the relationship between the powder characterization, the densification processes, and the changes in microstructure both with increasing temperature at a rate of 10° C min^–1 and at a fixed temperature of 1450° C for 5 h. The densification behaviour and the changes in microstructure of these compressed bodies were affected chiefly by their original surface activity and degree of agglomeration, depending on the production histories: (i) the ultra-fine and well-dispersed powder prepared by the vapour-phase oxidation process showed that densification proceeded with an appreciable grain growth with few closed pores remaining; (ii) powder derived from the sea-water magnesia process showed that the densification behaviour was affected by the species of magnesium salt, i.e. basic magnesium carbonate or magnesium hydroxide, used as a precursor; however, whichever magnesium salt was used, its sintered compact showed similar closed porosities and grain-size distributions; (iii) powder derived from the spark-discharge process contained skeletons of the original Mg(OH)₂ particles; however, the densification proceeded gradually with slow grain growth, reflecting the fact that the powder has a moderate surface area (36 m² g^–1). The sintered compact from (iii) had a small closed porosity and the smallest grain-size distribution among the compacts used in this investigation.     

Effect of transition elements on the properties of MC carbides in IN-100 nickel-based superalloy

The effect of nine transition elements on the morphology, distribution and composition of MC carbides (MCs) in a nickel-base superalloy, IN-100, was investigated by differential thermal analysis (DTA), microstructural observation and X-ray microanalysis. The doping with tantalum, tungsten and molybdenum caused a significant change in the morphology and distribution of MCs as well as the profile of DTA curve of IN-100. The compositions of the MC in IN-100 were TiC and (Ti_0.80Mo_0.17V_0.03) C, and the doping with niobium, tantalum and tungsten changed significantly the composition of MC. On the other hand, the doping with chromium, vanadium, hafnium and zirconium scarcely changed the composition. In addition to TiC and (Ti, Mo, V) C, zirconium- and hafnium-rich MCs were found in the zirconium- and hafnium-doped alloys, respectively. The effect of the dopants on the composition of MCs could be explained by a relationship between the metallic radius and the free energy of formation for the MC.     

A New Silicon Sensor for Hot Metal Measurements

In the present study, an electrochemical sensor has been designed for the direct measurement of silicon content in hot metal. The sensor represents a galvanic silicon concentration cell of the type Ni_sat—Si(1) II silicate electrolyte (1) II Fe—C—Si(1) The tubular silica-glass sensor can be immediately immersed into the metal bath at a response time of 30 to 60 s. A reproducible EMF vs. wt.% Si relationship was obtained for measurements in carbon-saturated Fe—C—Si melts at 1400°C and Si contents from 0.05 to 1.8 wt.%. This relationship is nearly identical with the cell function calculated from thermodynamic data.     

Three-dimensionally ordered macroporous polyimide composite membrane with controlled pore size for direct methanol fuel cells

Three-dimensionally ordered macroporous (3DOM) polyimide matrix with different pore size (1.3 μm–200 nm) was fabricated, and its structural effect on some properties of composite membrane was investigated. The composite membrane prepared by impregnation of 2-acrylamido-2-methylpropanesulfonic acid polymer (PAMPS) exhibited swelling ratios as low as 2–3% in water or methanol solutions, compared with about 400% of PAMPS itself. The swelling ratio of composite membrane was constant regardless of the 3DOM pore size. However, methanol permeability strongly depended on the pore size. In particular, it was drastically reduced when connecting windows among macropores became less than 100 nm. On the other hand, proton conductivity changed with 3DOM matrix porosity according to Archie's law. The porosity of 3DOM matrix is basically constant even if the pore size changes. Therefore, we suppressed the methanol crossover without lowering of proton conductivity due to reducing the matrix pore size, and the selectivity (proton conductivity/methanol permeability) of 1.2 × 10⁵ S cm⁻³ s, which was one order of magnitude greater than that of Nafion^®, was achieved.