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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Sensitivity Analysis of Material Model Parameters to Reproduce Crushing of Composite Tubes

The ability to predict the behavior of composite structures under impact conditions is an important challenge for engineering analysis since it requires modeling beyond the elasticity and into failure initiation and propagation. Crushing of laminate composites is the result of a combination of several and complex failure mechanisms, which are not always possible to reproduce together in a single finite element analysis (FEA). In this paper, models based on lamina-level failure criteria have been used to predict the onset of damage; once failure initiates, the mechanisms of failure propagation require reducing the material properties using several degradation schemes. Among the composite material models available in LS-DYNA, MAT-ENHANCED-COMPOSITE-DAMAGE (MAT-54) has been chosen for modeling the axial crushing of composite tubes with various resistant sections and wall slope, given the reduced experimental input parameters to insert into the card definition. Comparison with experimental data shows that such material model is able to successfully reproduce the crushing behavior, even if the numerical results are strictly correlated with some model parameters which cannot be measured experimentally or are purely mathematical expedients. Therefore, extensive calibration of these parameters by trial-and-error is necessary to achieve successful simulation results. Once done it for a structure made of the same composite material, it is possible to adopt the same card configuration for all the other cases, obtaining good agreement between numerical and experimental results. After, the attempt to model the same geometries using the MAT-LAMINATED-COMPOSITE-FABRIC (MAT-58) card with the same parameter values previously calibrated has been done obtaining results comparable with the experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mesostructure and porosity effects on the thermal conductivity of additively manufactured interpenetrating phase composites

In this paper, we have investigated the relationship between structure and thermal conductivity in additively manufactured interpenetrating A356/316L composites. We used X-ray microcomputed tomography to characterize the pore structure in as-fabricated composites, finding microporosity in both constituents as well as a 50 μm thick layer of interfacial porosity separating the constituents. We measured the thermal conductivity of a 43 vol% 316L composite to be 53 Wm -1 K -1 , which is significantly less than that predicted by a simple rule-of-mixtures approximation, presumably because of the residual porosity. Motivated by these experimental results we used periodic homogenization theory to determine the combined effects of porosity and unit cell structure on the effective thermal conductivity. This analysis showed that in fully dense composites, the topology of the constituents has a weak effect on the thermal conductivity, whereas in composites with interfacial porosity, the size and structure of the unit cell strongly influence the thermal conductivity. Finally, we also found that an approximation formula of the strong contrast expansion method gives excellent estimates of the effective thermal conductivity of these composites, providing a powerful tool for designing functionally graded composites and for identifying mesostructures with optimal thermal conductivity values.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Predicting effective thermal and elastic properties of cementitious composites containing polydispersed hollow and core-shell micro-particles

Micro- and nano-sized hollow and core-shell particles (CSPs) have attracted tremendous interests in developing functional cementitious composites and concretes. In this paper, a general method is developed to predict the thermal and elastic properties of cementitious composites containing core-shell and hollow micro-particles. The model follows a two-stage homogenization process – CSP inclusions together with their surrounding interfacial transition zone (ITZ) are first treated as equivalent solid particles, and then the homogenized properties of the composite system are obtained using numerical (i.e., finite element) or analytical (Mori-Tanaka) approaches. Compared with other homogenization methods, the proposed model is easy-to-use and versatile. The numerical model, validated by experimental results, is then used to guide the design of functional cementitious composites. The results show that CSP particle size (or relative shell thickness), volume fraction, shell property, and the size of the ITZ have significant impacts on the effective thermal and elastic properties of cementitious composites; whereas the particle size distribution pattern has relatively minor influence. In addition, the effective property of the composite is more sensitive to the particle property change when CSP inclusions are much stiffer or more thermally conductive than the matrix. Lastly, a scoping study is conducted to elucidate the relationship between the effective thermal conductivity and effective elastic moduli for cementitious composites containing CSP additives with different shell materials, particle sizes, and volume concentrations etc.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Compositional changes of dissolved organic molecules along water flow and their influencing factors in the Three Gorges Reservoir

Molecular composition of dissolved organic matter (DOM) and its influencing factors in river reservoirs remains elusive. Here, molecular compositions of DOM, bacterial community structures, and water physiochemistry were investigated in the field and microcosm samples of the Three Gorges Reservoir (TGR). The results showed that DOM molecular compositions were significantly (R 2 = 0.245, p < 0.001) correlated with bacterial community structures in the studied field samples, suggesting that bacteria may actively interact with DOM molecules. In this study, the molecular compositions of DOM in the studied field samples were significantly (p < 0.05) affected by the distance between the sample sites and the Three Gorges Dam and by bacterial groups of Actinobacteria and Alphaproteobacteria, suggesting that both hydrological and bacterial processes may contribute to the variation in DOM molecular composition in the TGR water. Furthermore, microcosm experiments demonstrated that both microbial and abiotic processes may transform and/or produce DOM in the TGR, thereby affecting DOM molecular composition. Microbial process increased the average aromaticity index and decreased the carbon number of DOM molecules with increasing incubation duration; whereas average oxygen number, double bond equivalent, and oxidation state of carbon of DOM molecules increased during the first 14 days of incubation and began to decrease thereafter. Taken together, this study expands our understanding of the impact of microbial process on the DOM molecular composition in reservoir ecosystems, and has great implications for carbon cycling in major rivers.

58 GEOSCIENCES↗
DOE OSTI2024

Metal-organic-framework and walnut shell biochar composites for lead and hexavalent chromium removal from aqueous environments

Extensive research in recent years has explored the realm of porous carbon composites for various applications, including electrochemistry, structural materials, environmental remediation, and more. In particular, the fabrication of porous carbon composites using a metal-organic framework (MOF) and biochar (BC) for aqueous remediation is a fairly new avenue of research. In this study, a MOF-BC composite was synthesized with unmodified and chemically modified BCs using solvothermal synthesis. The composites were used as adsorbents to remediate heavy metals, such as lead (II) and chromium (VI), from aqueous environments. Here, it was verified that the MOF was homogeneously deposited onto the BC's surface using various material characterization techniques. Lead and chromium adsorption studies revealed a high adsorption capacity with greater than 99% removal for lead and ∼65% for chromium, respectively. Impressively, for lead, the highest observed experimental adsorption capacity of the MOF-chemically modified BC composite was 535 mg/g, compared to 240 mg/g for pristine BC. Meanwhile, the adsorption capacity of the same MOF-BC composite for chromium ions was low at 18 mg/g, compared to 80 mg/g for the chemically modified BC. The MOF-BC had a rapid adsorption rate, achieving equilibrium at only 150 min of reaction time for lead ions. MOF-BCs have higher adsorption for cationic lead through physisorption and ion-exchange mechanisms, whereas, for anionic chromium, removal is dominated only by physisorption mechanisms. The outcomes and methodological developments attained in this study offer a novel and compelling approach for synthesizing MOF-BC composites for aqueous remediation applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Notch insensitivity in fatigue failure of chopped carbon fiber chip-reinforced composites using experimental and computational analysis

This study focuses on the notch effect on the fatigue failure of chopped carbon fiber chip-reinforced sheet molding compound (SMC) composites by using both experimental and numerical methods. The S-N diagrams of notched specimens are first obtained experimentally, which exhibit large scatter and are shown to depend on the spatial distribution of local fiber orientations. After considering the effect of this spatial distribution by adopting a new fatigue damage parameter to normalize the results, we achieve a much better correlation in the normalized S-N diagram for all the notched specimens with different hole diameters. Next, compared with the fatigue results of smooth specimens without notches, we find that SMC composites under tension-tension fatigue loading exhibit notch-insensitivity, which renders this type of composites a better candidate in joints or similar applications. Meanwhile, the fatigue failure mechanisms of notched SMC composites are explored through a microstructure characterization procedure. On this basis, a computational micromechanics model considering the notch effect and an improved multi-scale progressive damage fatigue law, calibrated by coupon-level fatigue tests of smooth SMC composites under different loading conditions, are employed to predict the fatigue behavior of notched SMC composites. We show that detailed failure processes and fatigue life of notched SMC composites can be efficiently and adequately predicted by this computational framework.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental and computational analysis of bending fatigue failure in chopped carbon fiber chip reinforced composites

With a better balance among good mechanical performance, high freedom of design, and low material and manufacturing cost, chopped carbon fiber chip reinforced sheet molding compound (SMC) composites show great potential in different engineering applications. Here in this paper, bending fatigue behaviors of SMC composites considering the heterogeneous fiber orientation distributions have been thoroughly investigated utilizing both experimental and computational methods. First, four-point bending fatigue tests are performed with designed SMC composites, and the local modulus is adopted as a metric to represent the local fiber orientation of two opposing sides. Interestingly, SMC composites with and without large discrepancy in local modulus of opposing sides show different fatigue behaviors. Interrupted tests are conducted to explore the bending fatigue failure mechanism, and the damage processes of valid specimens are also closely examined. We find that the fatigue failure of SMC composites under four-point bending is governed by crack propagation instead of crack initiation. Because of this, the heterogeneous local fiber orientations of both sides of the specimen influence fatigue life. The microstructure of the lower side shows a direct influence while that of the upper side also exhibiting influence which becomes more prominent for high cycle fatigue cases. Furthermore, a hybrid micro–macro computational model is proposed to efficiently study the cyclic bending behavior of SMC composites. The region of interest is reconstructed with a modified random sequential absorption algorithm to conserve all the microstructural details including the heterogeneous fiber orientation, while the rest of the regions are modeled as homogenized macro-scale continua. Combined with a framework to capture the progressive fatigue damage under cyclic bending, the bending fatigue behaviors of SMC composites are accurately captured by the hybrid computational model comparing with our experimental analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Superhydrophobic composite asymmetric electrospun membrane for sustainable vacuum assisted air gap membrane distillation

Membrane distillation (MD) relies on superhydrophobic membranes that must achieve the competing goals of high liquid entry pressure (LEP) and high permeability. Here, in this study, we developed the first superhydrophobic composite electrospun asymmetric membrane using fluorinated graphite (FG). We also provided among the first comparisons of the relative benefits of membrane asymmetry and composite coatings via 3D electrospinning and spraying. FG particles increased the roughness and reduced the zeta potential of the membranes. Superhydrophobic composite membranes had a contact angle of 157° (sliding angle of 7°) and an LEP of 327 kPa. Long-term MD testing revealed that FG particles could increase MD's sustainability while decreasing membrane wetting. Vacuum-assisted air gap membrane distillation (V-AGMD) showed that the composite asymmetric membrane outperformed the non-asymmetric version (composite nanofiber) membrane by 21 % in average water flux and 25 % in average thermal efficiency because of the asymmetric structure of the membrane. The numerical model developed for the V-AGMD system also successfully predicted the water flux generated experimentally from the composite nanofiber and composite asymmetric membranes. Our results confirmed that electrospun asymmetric FG membranes with high contact angle, low sliding angle, high permeability, and high gained output ratio (GOR) would be promising candidates for sustainable MD.

36 MATERIALS SCIENCE↗
DOE OSTI2019

High-dose, intermediate-temperature neutron irradiation effects on silicon carbide composites with varied fiber/matrix interfaces

SiC/SiC composites are promising structural candidate materials for various nuclear applications over the wide temperature range of 300–1000 °C. Accordingly, irradiation tolerance over this wide temperature range needs to be understood to ensure the performance of these composites. In this study, neutron irradiation effects on dimensional stability and mechanical properties to high doses (11–44 dpa) at intermediate irradiation temperatures (˜600 °C) were evaluated for Hi-Nicalon Type-S or Tyranno-SA3 fiber–reinforced SiC matrix composites produced by chemical vapor infiltration. The influence of various fiber/matrix interfaces, such as a 50–120 nm thick pyrolytic carbon (PyC) monolayer interphase and 70–130 nm thick PyC with a subsequent PyC (˜20 nm)/SiC (˜100 nm) multilayer, was evaluated and compared with the previous results for a thin-layer PyC (˜20 nm)/SiC (˜100 nm) multilayer interphase. Four-point flexural tests were conducted to evaluate post-irradiation strength, and SEM and TEM were used to investigate microstructure. Regardless of the fiber type, monolayer composites showed considerable reduction of flexural properties after irradiation to 11–12 dpa at 450–500 °C; and neither type showed the deterioration identified at the same dose level at higher temperatures (>750 °C) in a previous study. After further irradiation to 44 dpa at 590–640 °C, the degradation was enhanced compared with conventional multilayer composites with a PyC thickness of ˜20 nm. Multilayer composites have shown comparatively good strength retention for irradiation to ˜40 dpa, with moderate mechanical property degradation beginning at 70–100 dpa. As a result, irradiation-induced debonding at the F/M interface was found to be the major cause of deterioration of various composites.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Fabrication and thermophysical property characterization of UN/U 3 Si 2 composite fuel forms

High uranium density composite fuels composed of UN and U 3 Si 2 have been fabricated using a liquid phase sintering route at temperatures between 1873 K and 1973 K and spanning compositions of 10 vol% to 40 vol% U 3 Si 2 . Microstructural analysis and phase characterization revealed the formation of an U-Si-N phase of unknown structure. Microcracking was observed in the U-Si portion of the composite microstructure that likely originates from the mismatched coefficient of thermal expansion between the UN and U 3 Si 2 leading to stresses on heating and cooling of the composite. Thermal expansion coefficient, thermal diffusivity, and thermal conductivity were characterized for each of the compositions as a function of temperature to 1673 K. Hysteresis is observed in the thermal diffusivity for the 20 vol% through 40 vol% specimens between room temperature and 1273 K, which is attributed to the microcracking in the U-Si phase. Thermal conductivity of the composites was modeled using the MOOSE framework based on the collected microstructure data. In conclusion, the impact of irradiation on thermal conductivity was also simulated for this class of composite materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Solid state {sup 31}P MAS NMR spectroscopy and conductivity measurements on NbOPO{sub 4} and H{sub 3}PO{sub 4} composite materials

A systematic study of composite powders of niobium oxide phosphate (NbOPO{sub 4}) and phosphoric acid (H{sub 3}PO{sub 4}) has been performed in order to characterize the material's ability to perform as an electrolyte material in medium temperature fuel cells and electrolyzers. Powders of H{sub 3}PO{sub 4} contents between 13.1 and 74.2 M% were produced and characterized with powder X-ray diffraction, {sup 31}P MAS NMR and impedance spectroscopy. NMR revealed that a significant degree of dehydration and vaporization of H{sub 3}PO{sub 4} takes place above 200 °C, and increases with temperature. At 500 °C the NbOPO{sub 4} and H{sub 3}PO{sub 4} has reacted to form niobium pyrophosphate (Nb{sub 2}P{sub 4}O{sub 15}). Impedance spectroscopy showed an increase in conductivity with increasing acid concentration, whereas the conductivity decreased slightly with increasing temperature. The highest conductivity measured was 2.5·10{sup −3} S/cm for a sample containing 74.2 M% of H{sub 3}PO{sub 4}. Lastly, it was shown that NbOPO{sub 4} has no significant conductivity of its own. - Graphical abstract: Conductivity of NbOPO{sub 4}/H{sub 3}PO{sub 4} composites as a function of equivalent P{sub 2}O{sub 5} content. The conductivity is insignificant for pure NbOPO{sub 4}. - Highlights: • Composites have been made from NbOPO{sub 4} and H{sub 3}PO{sub 4}. • The composites composition has been investigated with solid state NMR. • The composites have shown clear signs of acid dehydration upon heating. • The conductivity of the composites increases for increasing acid content. • NbOPO{sub 4} has no significant conductivity of its own.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2013

Effect of re-melting on particle distribution and interface formation in SiC reinforced 2124Al matrix composite

The interface between metal matrix and ceramic reinforcement particles plays an important role in improving properties of the metal matrix composites. Hence, it is important to find out the interface structure of composite after re-melting. In the present investigation, the 2124Al matrix with 10 wt.% SiC particle reinforced composite was re-melted at 800 °C and 900 °C for 10 min followed by pouring into a permanent mould. The microstructures reveal that the SiC particles are distributed throughout the Al-matrix. The volume fraction of SiC particles varies from top to bottom of the composite plate and the difference increases with the decrease of re-melting temperature. The interfacial structure of re-melted 2124Al–10 wt.%SiC composite was investigated using scanning electron microscopy, an electron probe micro-analyzer, a scanning transmission electron detector fitted with scanning electron microscopy and an X-ray energy dispersive spectrometer. It is found that a thick layer of reaction product is formed at the interface of composite after re-melting. The experimental results show that the reaction products at the interface are associated with high concentration of Cu, Mg, Si and C. At re-melting temperature, liquid Al reacts with SiC to form Al{sub 4}C{sub 3} and Al–Si eutectic phase or elemental Si at the interface. High concentration of Si at the interface indicates that SiC is dissociated during re-melting. The X-ray energy dispersive spectrometer analyses confirm that Mg- and Cu-enrich phases are formed at the interface region. The Mg is segregated at the interface region and formed MgAl{sub 2}O{sub 4} in the presence of oxygen. The several elements identified at the interface region indicate that different types of interfaces are formed in between Al matrix and SiC particles. The Al–Si eutectic phase is formed around SiC particles during re-melting which restricts the SiC dissolution. - Highlights: • Re-melted composite shows homogeneous particle distribution • Thick reaction products are observed at the interface • Carbide is identified at interface due to SiC dissolution at high temperature • Reaction products are also Si enrich phase • Mg and Cu segregated and formed MgAl{sub 2}O{sub 4}, CuMgAl{sub 2} phase at grain boundary.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Micro-CT analysis and mechanical properties of Ti spherical and polyhedral void composites made with saccharose as a space holder material

The paper describes the formation, morphology and mechanical properties of Ti void composites. The Ti void composites were made using 100 and 325 mesh Ti powder for solid scaffold formation. The spherical and polyhedral voids (pores) were formed using saccharose particles (table sugar) of different shapes. The Ti void composite morphology was investigated by microcomputed tomography and scanning electron microscopy. The Ti void composites of designed porosity of 50–70% were made. Compression test was applied for mechanical properties estimation. It has been found, that Ti void composites made from 100 mesh Ti and those having spherical pores have a higher strength and elastic modulus, i.e. for the designed porosity of 50% for 100 and 325 mesh Ti void composites, a compressive strength was 32.32 and 20.13 MPa, respectively. It has been shown that this is related to better sintering of the 100 mesh Ti powders compared with the 325 mesh Ti powders. A correlation between microcomputed tomography data and mechanical properties has also been shown. The Ti void composites, made with the use of saccharose as a space holder, described in this work should be a promising material for biomedical applications, where interconnected pores and good mechanical properties are required. - Highlights: • Ti scaffolds of the porosity of 50–70% were made. • Saccharose particles as space holder were applied. • The voids in the scaffolds were designed with spherical and polyhedral shape. • The scaffold structure was investigated by SEM and micro-CT. • Micro-CT data and mechanical properties of the Ti scaffold have been correlated.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Study on hot deformation behavior and workability of squeeze-cast 20 vol%SiCw/6061Al composites using processing map

Highlights: • Prasad’s and Murty’s criteria were better than Gegel’s criterion in predicting the flow instability for the composites. • Partial melting and DRX at high temperature and high strain rate improved the workability of the composites. • The softening mechanism changed from DRV to DRX with the increase of deformation temperature and strain rate. • The safe deformation region of the composites was at higher temperature of 450-500°C and higher strain rate of 0.1-1s{sup -1}. • The safe deformation region predicted by processing maps was validated by uniaxial upsetting and two-directional forging. - Abstract: The hot deformation behavior and workability of squeeze-cast 20 vol%SiCw/6061Al composites were investigated by isothermal compression test and development of processing map, which was verified by uniaxial upsetting and two-directional forging of big cylindrical billets. Due to dispersed strengthening caused by SiC whiskers, the activation energy of 20 vol%SiCw/6061Al composites was much higher than the self-diffusion activation energy of pure Al. Both the DMM and MDMM were reliable in predicting the safe deformation regions. The instability regions predicted by the Prasad's and Murty's instability criterion were smaller than the actual ones, while the Gegel's instability criterion was not appropriate in predicting the instability regions of 20 vol%SiCw/6061Al composites. The optimum deformation region was at higher temperature of 450–500 °C and higher strain rate of 0.1–1 s{sup − 1}, in which the compressed samples exhibited perfect surface without cracks and microstructure with few of cavities due to the occurrence of partial melting and dynamic recrystallization. With the increase of deformation temperature and strain rate, the deformation mechanism changed from dynamic recovery to dynamic recrystallization. Squeezing casting technique with high filtration pressure may also contribute to the increase of strain rate of DRX, which was helpful for hot forging of Al matrix composites with high productivity.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Agro-waste shaped porous Al2O3/Ni composites: Corrosion resistance performance and artificial neural network modelling

Highlights: • Porous Al{sub 2}O{sub 3}/Ni composites were developed with agro-waste pore-forming agents. • The RH and SCB graded composites showed Ni{sub 3}Al{sub 2}SiO{sub 8} and NiAl{sub 2}O{sub 4} spinels respectively. • Superior chemical stability was demonstrated by the Al{sub 2}O{sub 3}-2Ni-RH composite. • The ANN model demonstrated a good performance with R{sup 2} value of approx. 0.99. - Abstract: In the present study, an analysis on the combined effect of nickel (Ni) reinforcement and pore former type in characterizing the corrosion behavior of composite porous alumina ceramics was performed. In order to showcase the potential of the new porous ceramics, pore-forming agents (PFAs) from rice husk (RH) and sugarcane bagasse (SCB) were used in shaping the plain and composite porous alumina samples having sample formulation of Al{sub 2}O{sub 3}-xNi-PFA; x = 0, 2, 4, 6 and 8 wt%. Results showed that the emergence of a highly stable Ni{sub 3}Al{sub 2}SiO{sub 8} spinelloid phase in the RH-graded composites enhanced their chemical stability in the corrosive mediums (10 wt% NaOH and 20 wt% H{sub 2}SO{sub 4}) relative to the plain and the corresponding SCB-graded counterparts. An artificial neural network (ANN) model has been developed for predicting the corrosion behavior of the plain and composite porous alumina ceramics based on the experimental data. The developed ANN model satisfactorily predicted the percent mass losses of the porous ceramics in strong alkali and strong acid solutions with coefficient of determination (R{sup 2}) of approximately 0.99.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Development of pore-free Ti-Al-C MAX/Al-Si MMC composite materials manufactured by squeeze casting infiltration

Highlights: • Open-porous MAX phase preforms were synthesized by Microwave Assisted Self-propagating High-temperature Synthesis • Manufactured preforms were infiltrated by Al-Si alloy with the use of Squeeze Casting method to create pore-free composites • Obtained materials were characterized by the means of SEM, TEM and XRD analyses • Mechanical properties were tested and discussed in relation to the microstructures An innovative method of manufacturing of Ti-Al-C MAX/Al-Si MMC composite materials was developed using squeeze casting infiltration of open-porous MAX phase preforms. Self-propagating High-temperature Synthesis (SHS) in microwave-assisted mode was applied for the creation of preforms in the Ti-Al-C system, that were subsequently infiltrated with Al-Si alloy to create dense composite materials. Microstructure and phase composition, structural defects and potential impacts between constituents of manufactured composites were characterized by the means of SEM and TEM microscopies and XRD analysis. No undesired reaction at the interface was observed, but TiC inclusions were identified in the material. Among the mechanical properties, the instrumental Young's modulus and Vickers hardness were established. The hardness and the elastic modulus of the matrix were enhanced 4 to 5 times. Wear behaviour was tested with a “pin-on-flat” method with the reciprocating motion for different load values (0.1, 0.2 and 0.5 MPa) for tool steel counterpart. Wear resistance of the composite material (WR = 1.6–2.3 × 10{sup −4} mm{sup 3}/Nm) was twofold higher than for the sole matrix (WR = 3.5–4.8 × 10{sup −4} mm{sup 3}/Nm). The developed manufacturing method allows the effective fabrication of pore-free MAX phase based MMC composite materials, with significantly higher wear resistance than the widely applied Al-Si alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Synthesis and characterization of aluminium–alumina micro- and nano-composites by spark plasma sintering

Graphical abstract: The evolution of microstructure by varying the particle size of reinforcement in the matrix employing spark plasma sintering has been demonstrated here in Al–Al{sub 2}O{sub 3} system. An emphasis has been laid on varying the reinforcement particle size and evaluating the microstructural morphologies and their implications on mechanical performance of the composites. Nanocomposites of 0.5, 1, 3, 5, 7 volume % alumina (average size < 50 nm) reinforced in aluminium matrix were fabricated by powder metallurgy route using spark plasma sintering technique technique at a temperature of 773 K and pressure of 50 MPa. Another set of specimens having composition 1, 5, 20 vol.% of alumina (average size ∼ 10 μm) had been fabricated to compare the physical as well as mechanical attributes of the microcomposite as well as the nanocomposites. These micro- and nano-composites have been characterized using X-ray diffraction, scanning electron microscopy and transmission electron microscopy followed by density, microhardness and nanoindentation measurements. The alumina nanoparticles revealed an interface showing appreciable physical intimacy with the aluminium matrix compared to that of the alumina microparticles. The interfacial integrity in case of nanocomposites is better than in the microcomposite which has been studied using microscopic techniques. Spark plasma sintering imparts enhanced densification as well as matrix-reinforcement proximity which has been corroborated with the experimental results. - Highlights: • The Al–Al{sub 2}O{sub 3} micro- and nano-composites fabricated by spark plasma sintering. • Better matrix-reinforcement integrity in nanocomposites than microcomposites. • Spark plasma sintering method results in higher density and hardness values. • High density and hardness values of nanocomposites than microcomposites. • High dislocation density in spark plasma sintered Al–Al{sub 2}O{sub 3} composites. - Abstract: In the present study, an emphasis has been laid on evaluation of the microstructural morphologies and their implications on mechanical performance of the composites by varying the reinforcement particle size. Nanocomposites of 0.5, 1, 3, 5, 7 volume % alumina (average size < 50 nm) and microcomposites of 1, 5, 20 volume % of alumina (average size ∼ 10 μm) reinforced in aluminium matrix were fabricated by spark plasma sintering technique at a temperature of 773 K and pressure of 50 MPa. These micro- and nano-composites have been characterized using X-ray diffraction, scanning electron microscopy and transmission electron microscopy followed by density, microhardness and nanoindentation hardness measurements. The alumina nanoparticles revealed appreciable physical intimacy with the aluminium matrix than that of alumina microparticles. The highest nanohardness recorded 0.85 GPa and 99% densification for 7 and 1 vol.% Al–Al{sub 2}O{sub 3} nancomposites respectively. Spark plasma sintering imparts enhanced densification and matrix-reinforcement proximity which have been corroborated with the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Synthesis of Cu-Fe{sub 3}O{sub 4}@graphene composite: A magnetically separable and efficient catalyst for the reduction of 4-nitrophenol

Highlights: • The Cu-Fe{sub 3}O{sub 4}@GE composite was prepared by one-step solvent–thermal method. • The Cu-Fe{sub 3}O{sub 4}@GE composite exhibited the highest catalytic activity with excellent stability. • The Cu-Fe{sub 3}O{sub 4}@GE composite was magnetically separable. - Abstract: In this work, the Cu-Fe{sub 3}O{sub 4}@GE composite was prepared easily by a one-step solvent–thermal method, which achieved the formation of Cu nanoparticles (Cu NPs), Fe{sub 3}O{sub 4} nanoparticles (Fe{sub 3}O{sub 4} NPs) and reduction of GO simultaneously. The morphology and structure of the composite was fully characterized by means of X-ray diffraction (XRD), Fourier transformed infrared (FTIR) spectroscopy, transmission electron microscopy (TEM). The time-dependent adsorption spectra of the reaction mixture was measured by UV–vis absorption spectroscopy. The results demonstrated that the Cu NPs and Fe{sub 3}O{sub 4} NPs were densely and evenly deposited on the graphene (GE) sheets. It was found that the Cu-Fe{sub 3}O{sub 4}@GE composite exhibited high catalytic activities on the reduction of p-nitrophenol to p-aminophenol. Furthermore, the composite catalyst can be easily recovered due to its magnetic separability and high stability.

36 MATERIALS SCIENCE↗