Additive manufacturing of alumina parts by indirect selective laser sintering and post processing

Innovative powder preparation and post-processing techniques can be employed to obtain high density ceramic parts by means of indirect selective laser sintering. Thermally induced phase separation (TIPS) was used to produce polymer and polymer–ceramic composite particles. The effect of polymer concentration, cooling rate, stirring and alumina particles on polymer and polymer–ceramic composite particles was investigated. Homogeneous spherical alumina–polypropylene (PP) composite powder was synthesized by TIPS for selective laser sintering (SLS). Green Al₂O₃–PP component parts with a density of 34% could be produced by conventional SLS of the polymer under optimized laser power, scan speed, scan spacing and powder preheating temperature. Various post-processing techniques like pressure infiltration (PI), warm isostatic pressing (WIPing) or a combination of both were applied to increase the green density of the Al₂O₃–PP SLM parts. Infiltrating the open porosity green SLS parts with a 30 vol% alumina-powder based ethanol suspension allowed to increase the sintered density, i.e. after polymer debinding and pressureless sintering in air at 1600 °C, from 38 to 64% of the theoretical density (TD). WIPing of the SLS and SLS/infiltrated green parts at 135 °C and 64 MPa allowed raising the green density up to 93 and 83% TD and a sintered density up to 89 and 88% TD, respectively.     

Non-monotonic lattice parameter variation with crystallite size in nanocrystalline solids

An anomalous dependence of the lattice parameter on the crystallite size of nanocrystalline ball-milled powders of metals was observed: lattice contraction followed by lattice expansion with decreasing crystallite size. These data were determined by application of detailed X-ray diffraction measurements. To this end the lattice parameters of the metals investigated – nickel, copper, iron and tungsten – were precisely determined by correcting for influences of stacking faults, in the face-centred cubic metals, as well as by correcting for instrument-related aberrations. The non-monotonic variation of the lattice constant was interpreted as the result of two competing mechanisms: interface-stress-induced contraction vs. expansion as a result of the stress field generated at the crystallite boundary due to the increased excess free volume in the crystallite boundary upon decreasing crystallite size.     

Polypyrrole and polyaniline prepared with cerium(IV) sulfate oxidant

The conducting polymers, polypyrrole and polyaniline, were synthesized by chemical oxidative polymerization of the corresponding monomers in 0.1 M sulfuric acid using cerium(IV) sulfate as the oxidant at mole ratios of oxidant-to-monomer ranging from 0.5 to 3. The yields of the oxidation products were determined, and the samples were characterized with respect to their elemental composition, molecular structure, and morphology. The conductivity of polypyrrole prepared in 0.1 M sulfuric acid, 10^?1 to 10⁰ S cm^?1, was higher compared with the conductivity of polyaniline prepared under the same conditions, 10^?3 to 10^?1 S cm^?1. The loss of mass after deprotonation with ammonium hydroxide is reported, and discussed in terms of the type of protonation as also reflected by FTIR spectroscopy. The conductivity of polypyrrole bases remained at relatively high level, 10^?5 to 10^?3 S cm^?1, while PANI bases became non-conducting, 10^?12 to 10^?10 S cm^?1. The polymers had a granular morphology in all cases.     

High mobility n-channel organic field-effect transistors based on soluble C60 and C70 fullerene derivatives

We report on n-channel organic field-effect transistors (OFETs) based on the solution processable methanofullerenes [6,6]-phenyl-C₆₁-butyric acid ester ([60]PCBM) and [6,6]-phenyl-C₇₁-butyric acid methyl ester ([70]PCBM). Despite the fact that both derivatives form glassy films when processed from solution, their electron mobilities are high and on the order of 0.21 cm²/V s and 0.1 cm²/V s, for [60]PCBM and [70]PCBM, respectively. Although the derived mobility of [60]PCBM is comparable to the best values reported in the literature, the electron mobility of [70]PCBM is the highest value reported to date for any C₇₀ based molecule. We note that this is the only report in which C₆₀ and C₇₀ methanofullerenes exhibit comparable electron mobilities. The present findings could have significant implications in the area of large-area organic electronics and organic photovoltaics where C₆₀ derivatives have so far been the most widely used electron acceptor materials.     

The Effect of Heat Treatment on the Microstructure and Properties of Explosively Welded Titanium-Steel Plates

This paper describes a study of explosively welded titanium-carbon steel S355J2+N plates. Following the welding, plates underwent heat treatment at temperature of 600 °C for 90 min with cooling in furnace to 300 °C and in air to room temperature. The structure of the bonding was examined by using light, scanning electron (SEM) and transmission electron microscopy. The mechanical properties before and after heat treatment were examined applying three-point bending tests with cyclic loads and hardness measurements. Fracture surfaces were investigated using computer tomography and SEM. It has been found that the bonding areas are characterized by a specific chemical composition, microstructure and microhardness. Between the steel and the Ti cladding, a strongly defected transition zone was formed and melted areas with altered chemical composition were observed. It was also demonstrated that the heat treatment commonly applied to welded steel-Ti plates had a significant and negative impact on the microstructure and mechanical properties of the welded plates due to formation of brittle intermetallic phases.     

Analysis and specification of the crash behaviour of plastics/metal-hybrid composites by experimental and numerical methods

Plastics materials are nowadays used in many structural applications for the substitution of metals with respect to weight reduction. In order to utilize the high freedom of design and the light-weight potential of plastics materials in crash-relevant structural parts, so-called hybrid composites which combine the high rigidity and strength of steel with the advantages of plastics materials are investigated in the outlined research. Thereby, the joining of both materials as well as the design by means of numerical methods such as the finite element analysis (FEA) are challenges which have to be met. A new approach in joining is based on the modified arc welding process where metal pin structures are formed in one working step and subsequently welded onto the surface. The pins are formed with ball-shaped, cylindrical or spiky ends and produced directly from the welding wire without requiring additional pre-fabricated components such as studs or similar. This allows the small-scale surface structuring of metal components that can be adapted optimally for a form fit on the respective plastics structure. Subsequently, injection molding is used for the application of the plastics material onto the pin-structured metal part in order to generate a positive fit between metal and plastics in an intrinsic joining process. An additional joining process, which is carried out after injection molding, is not required. Within the framework of the research presented, comprehensive mechanical tests are presented to illustrate the suitability of pin-structured metal-hybrid composites in crash applications. In comparison to structures which are in particular exposed to static loads and therefore designed to exhibit maximum component strength, crash applications are designed to fail in a continuous process to achieve maximum energy consumption. The outlined research illustrates the enhanced failure behavior of pin-structured plastics/metal-hybrid composites and the increased energy consumption under impact loading. Moreover, a comparison between pin structuring and laser structuring with regard to the obtainable mechanical properties under impact loading is given. Concluding, the current potential and weak points in the simulation of plastics/metal-hybrid structures using FEA is presented and discussed.     

Leaching of blended copper slag in microwave oven

Leaching of blended slag (BS) was investigated in a microwave oven using hydrogen peroxide and acetic acid. The BS was a mixture of converter and flash furnace slag containing 51% Fe₂O₃, 3.8% CuO, and 3.2% ZnO. The important variables that influence the metal extraction yield were leaching time, liquid-solid ratio, H₂O₂ and CH₃COOH concentrations. The preferred leaching conditions were as follows: CH₃COOH concentration 4 mol/L; H₂O₂ concentration 4 mol/L; microwave power 900 W; leaching time 30 min; liquid-solid ratio 25 mL/g BS; leaching temperature 100 °C. Under these conditions, the metal extractions of 95% Cu, 1.6% Fe, and 30% Zn were obtained. The results were compared with the traditional leaching results. It is evident that microwave heating causes a reduction in the leaching time. Also, the extraction yield results indicate that selective leaching of BS can be achieved under the preferred conditions. The dissolution kinetic of BS in hydrogen peroxide with acetic acid is controlled by a shrinking unreacted core model equation. The apparent activation energy and reaction order were found to be 16.64 kJ/mol and 1.09, respectively.     

Study of hybrid PVD–PECVD process of Ti sputtering in argon and acetylene

Hybrid PVD–PECVD process of target sputtering in hydrocarbon containing atmosphere combines aspects of both conventional reactive magnetron sputtering (PVD) and plasma enhanced chemical vapour deposition (PECVD). Such process is being typically used for deposition of metal carbides embedded in hydrogenated carbon matrix. Compared to the conventional co-sputtering of metal and carbon targets, in the hybrid deposition process the source of the carbon is dissociated hydrocarbon vapour in plasma. The aim of this paper is to study the extent of similarities or differences between this hybrid process and the conventional reactive magnetron sputtering. We have chosen the sputtering of titanium target in acetylene containing atmosphere as a representative of the hybrid processes. We focused on experimental measurements of the hybrid PVD–PECVD process behaviour, the time necessary for the process to achieve steady-state conditions and basic modelling of the process.