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At least 163 records · Page 9

Al{sub 2}O{sub 3}-TiC Composite Prepared by Spark Plasma Sintering Process: Evaluation of Mechanical and Tribological Properties

Al{sub 2}O{sub 3}-10TiC composites were synthesized by spark plasma sintering (SPS) process. Microstructural and mechanical properties of the composite reveal homogeneous distribution of the fine TiC particles in the matrix. The samples were produced with different sintering temperature, and it shows that the hardness and density gradually increases with increasing sintering temperature. Abrasion wear test result reveals that the composite sintered at 1500 °C shows high abrasion resistance (wt. loss ~ 0.016 g) and the lowest abrasion resistance was observed for the composite sample sintered at 1100 °C (wt. loss ~ 1.459 g). The profilometry surface roughness study shows that sample sintered at 1100 °C shows maximum roughness (R{sub a} = 6.53 µm) compared to the sample sintered at 1500 °C (R{sub a} = 0.66 µm) corroborating the abrasion wear test results.

36 MATERIALS SCIENCE↗

Densification and oxidation behavior of spark plasma sintered Hafnium Diboride-Hafnium Carbide composite

This study reports on the sintering and oxidation behaviors of Hafnium Diboride (HfB 2 ) and Hafnium Carbide (HfC) based ultra-high temperature ceramic (UHTC) composites. Pure Hafnium Diboride, Hafnium Carbide, and HfB 2 -50 vol% HfC composite were consolidated using spark plasma sintering (SPS) without the use of sintering aids. HfB 2 -HfC composite displayed a high sintered density of 98% as compared to 87% density of pure HfB 2 . The increased density of the HfB 2 -HfC composite is attributed to the bimodal powder distribution, which allowed for the smaller HfC particle to occupy the voids between the larger HfB 2 particles resulting in improved packing efficiency. Moreover, the higher planar surface energy, for the (111) and the (200) planes for HfC, contributed to the smaller HfC particle being a significant driving force in the sintering process. Oxidation studies of each material were carried out by exposing them to a high-speed plasma jet in a temperature exceeding 2700 °C. The results of these studies show an improved oxidation resistance of HfB 2 -HfC composite by 54% and 70% over pure HfC and HfB 2 , respectively. The enhanced oxidation behavior is attributed to B 2 O 3 filling in the porosity between the HfO 2 scale and protecting the underlying material. This study provides a new alternative to improve the sinterability of UHTC diborides by introducing another UHTC (i.e., HfC) to form a fully dense composite without sintering aid and superior oxidation resistance.

36 MATERIALS SCIENCE↗

A study on the sintering of ultrafine grained tungsten with Ti-based additives

Tungsten (W) is a brittle material at room temperature making it very difficult to fabricate. Although the lack of ductility remains a difficult challenge, nano-sized and ultrafine grain (UFG) microstructures offer potential for overcoming tungsten's room temperature brittleness. One way to manufacture UFG W is to compact and sinter nanosized W powder, however, it is a non-trivial task to control grain growth during sintering. In an effort to inhibit grain growth, the effect of Ti-based additives on the densification and grain growth of nano-W powders was investigated here in this study. The addition of 1 wt.% Ti into tungsten led to more than a 63% decrease in average grain size of sintered samples at comparable density levels. It was also found that sintering in Ar yielded a finer grain size than sintering in H 2 at similar densities. Compared to conventional high temperature sintering, a lower temperature sintering cycle for a longer hold time resulted in both near-full density and fine grain size. The roles of the Ti additive include not only the inhibition of grain growth, but also the potential absorption of oxygen from W particles.

36 MATERIALS SCIENCE↗

Manufacturing porous U-10Zr metallic fuels with controllable microstructure by volume control spark plasma sintering

In this paper, the volume control spark plasma sintering tool has been designed and applied to sinter porous U-10Zr metallic fuels, by which the sintered sample volume can be precisely controlled. Ethanol and NH 4 HCO 3 are used to control the powder compact or as pore formers to control the pore size and pore structure. Without pore formers, the fuel pellet displays an inhomogeneous microstructure consisting of highly porous and highly densified areas. Uneven powder stacking in the green body results in a non-uniform microstructure, and in the closed-packed area, Joule heating accelerates the neck formation and densification. The addition of ethanol reduces the friction between the powders, resulting in isolated pores formed by the stacking of powders during the sintering. By adding NH 4 HCO 3 , the pore size, and structure can be well controlled, and an interconnected pore structure can be obtained upon the decomposition of the NH 4 HCO 3 . Further, a uniform microstructure and pore distributions can be achieved through the U-10Zr fuel pellets by controlling current flow during the volume control SPS sintering. The microstructure and phase characterization of the sintered porous U-10Zr pellets show major phases of α-U and α-Zr for the sample with short dwelling. For the sample with long dwelling (30 min), the ω UZr 2 in the Zr-enriched area has been observed. The strategy of volume control SPS sintering with the assistance of pore formers could be used to fabricate porous U-10Zr metallic fuels to mimic the microstructure evolution of irradiated metallic fuels (including porosity) and could enable a possible solution for the design of new sodium-free metallic fuels for high burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Surface phenomena during the early stages of sintering in steels modified with Fe–Mn–Si–C master alloys

The characteristics of the metallic powder surface play a critical role in the development of strong bonds between particles during sintering, especially when introducing elements with a high affinity for oxygen. In this study, Mn and Si have been combined in a Fe–Mn–Si–C master alloy powder in order to reduce their chemical activity and prevent oxidation during the heating stage of the sintering process. However, when this master alloy powder is mixed with an iron base powder, differences in chemical activity between both components can lead to an oxygen transfer from the iron base powder to the surface of the master alloy particles. The present research is focused on studying the evolution of the master alloy particle surface during the early stages of sintering. Surface characterization by X-ray Photoelectron Spectroscopy (XPS) shows that the master alloy powder surface is mostly covered by a thin easily reducible iron oxide layer (∼ 1 nm). Mn–Si particulate oxides are found as inclusions in specific areas of the surface. Evolution of oxides during sintering was studied on green compacts containing iron powder, graphite and Fe–Mn–Si–C master alloy powder that were heat treated in vacuum (10{sup −6} mbar) at different temperatures (from 400, 600, 800 to 1000 °C) and analyzed by means of XPS. Vacuum sintering provides the necessary conditions to remove manganese and silicon oxides from the powder surface in the range of temperatures between 600 °C and 1000 °C. When sintering in vacuum, since the gaseous products from reduction processes are continuously eliminated, oxidation of master alloy particles due to oxygen transfer through the atmosphere is minimized. - Highlights: • Mn and Si were introduced in sintered steels using a master alloy powder. • Surface of the master alloy is mainly covered by an easily reducible iron oxide. • Temperature ranges for oxidation/reduction are identified. • Vacuum conditions avoid oxygen transfer to oxidation sensitive elements. • Chemical activity of Mn and Si is lowered when combined in a form of master alloy.

36 MATERIALS SCIENCE↗

Linking sintering stresses to nano modification in the microstructure of BaLa4Ti4O15 by transmission electron microscopy

Highlights: • by systematic HRTEM studies we link the microstructural changes in BLT ceramics to the external pressure applied during sintering; • we developed a mechanistic understanding of the role of stress in sintering; • external stresses during sintering affect the microstructural development at the nanoscale level, being responsible for the creation of higher defective bulk and grain boundary regions; • observation of high density of stacking faults (which generally arrises due to the Ti vacancy layers) indicates that the applied stress is modifying the stacking of AO{sub 3} layers of BLT which in turn creates Ti vacancy layer and stacking faults; • stress assisted sintering has, therefore, the potential to be used as a tool to design microstructures and achieve tailored properties, as suggested from our previous results in BLT and BNT. - Abstract: High quality factor and a temperature stable resonant frequency make BaLa{sub 4}Ti{sub 4}O{sub 15} (BLT) ceramics attractive materials for microwave applications. Aiming to exploit the effects of external stresses on the development of textured and anisotropic microstructures to optimise MW properties, the influence of applied external pressure during sintering of BLT ceramics is analysed. HRTEM and geometric phase analysis (GPA) showed that stresses applied during sintering, trigger the nucleation and growth of faults hypothesised to be due to the errors in the AO{sub 3} layer (basal plane) stacking sequence of the hexagonal perovskite structure. The results reveal a strong correlation between the high concentration of structural defects and the development of anisotropic microstructures, which tune the properties of BLT. Stresses applied during sintering are therefore a promising tool to design material properties.

36 MATERIALS SCIENCE↗

Effect of the sintering temperature on the properties of Ce{sub 0.85}La{sub 0.10}Ca{sub 0.05}O{sub 2-{delta}} electrolyte material

Rare earth and alkaline earth co-doped Ce{sub 0.85}La{sub 0.10}Ca{sub 0.05}O{sub 2-{delta}} electrolyte material with the powder obtained by solid-state reaction method was sintered at 1300, 1400, 1500 and 1600 {sup o}C respectively. The results showed that the ionic conductivity of the sample sintered at 1400 {sup o}C was slightly lower compared to that sintered at 1500 {sup o}C in the temperature range of 300-550 {sup o}C, while the sample sintered at 1400 {sup o}C showed the highest ionic conductivity in all the samples above 550 {sup o}C. The ionic conductivity of {approx}0.021 S/cm at 600 {sup o}C and the relative density of 98.2% were observed for the sample sintered at 1400 {sup o}C. In addition, the highest flexural strength with 145 MPa was also obtained for the sample sintered at 1400 {sup o}C. It suggested that the sintering temperature for Ce{sub 0.85}La{sub 0.10}Ca{sub 0.05}O{sub 2-{delta}} electrolyte may be reduced to as low as 1400 {sup o}C with desired properties.

36 MATERIALS SCIENCE↗

Grain boundary scavenging through reactive sintering of strontium and iron in samarium doped ceria electrolyte for ITSOFC applications

Highlights: • Addition of iron and strontium to Samarium doped ceria by combustion method and sintered at 1000 °C, 1200 °C, 1300 °C. • Viscous phase sintering of iron at 1200 °C modified to reactive sintering of iron and strontium at 1300 °C. • Grain boundary activation energy lowered without compensating the grain activation energy. • The highest scavenging factor of 10.52 with the lowest activation energy of 1.02eV was achieved. - Abstract: Lowering the operational temperature of ceria based electrolytes is important for commercialization of solid oxide fuel cells. Here, we report the effect of iron, strontium and iron/strontium co-addition in samarium (20 mol %) doped ceria (SDC) with respect to sintering, microstructural modifications and ionic conductivity. The nanoparticle synthesized through glycine-nitrate combustion method was sintered at 1000, 1200 and 1300 °C. An increase in density was observed in iron doped SDC due to viscous flow sintering while co-addition of strontium and iron lead to the reactive sintering at 1300 °C by forming a eutectic liquid phase which resulted in the density of 99%. The presence of iron and strontium generated a compensatory tensile strain in the lattice and an enhancement in oxygen vacancy concentration which resulted in higher ionic conductivity. Co-addition of strontium and iron in SDC, not only increases the density but also reduces the activation energy for grain boundary conductivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Enhanced dielectric constant and relaxor behavior realized by dual stage sintering of Sr{sub 0.5}Ba{sub 0.5}Nb{sub 2}O{sub 6}

The relaxor ferroelectric compound, Sr{sub 0.5}Ba{sub 0.5}Nb{sub 2}O{sub 6} (SBN50) was synthesized by solid state reaction followed by sintering under two different conditions: single and dual stage sintering. The impact of sintering process on structural and dielectric properties has been studied in detail using X-ray diffraction, scanning electron microscopy and broadband dielectric spectroscopy. The crystal structure determined by performing Rietveld refinement of X-ray diffractogram was found to be identical in both cases. SBN50 crystallizes in the ferroelectric tetragonal tungsten bronze, P4bm structure. It was observed that uniform grain growth can be controlled by dual stage sintering and relatively narrow distribution of grains can be achieved with an average grain size of ∼15 μm. The dielectric studies show that SBN50 exhibits a relaxor ferroelectric behavior with the transformation taking place at ∼ 380 K due to formation of polar nano regions. Although both single and dual stage sintered SBN50 exhibits relaxor behaviour, the maximum dielectric constant of dual stage sintered SBN50 is found to be 1550 compare to 1440 for single stage sintering.

36 MATERIALS SCIENCE↗

The microwave effects on the properties of alumina at high frequencies of microwave sintering

Microwave sintering of materials has attracted much research interest because of its significant advantages (e.g. reduced sintering temperatures and soaking times) over the conventional heating. Most researchers compared processes that occurred during the microwave and conventional heating at the same temperature and time. The enhancements found in the former method are indicated as a 'non-thermal effect' which is usually used for explaining the phenomena in microwave processing. Numerous recent studies have been focused on the effect to elucidate the microwave interaction mechanism with materials. Moreover, recent progress on microwave sources such as gyrotrons has opened the possibility for processing materials by using a higher microwave frequency. Therefore, the technology is expected to exhibit a stronger non-thermal effect. This paper presents results from a series of experiments to study the non-thermal effect on microwave sintered alumina. Sintering by using a wide rage of microwave frequencies up to 300 GHz as well as a conventional furnace was carried out. The linear shrinkages of samples for each sintering method were measured. Pores and grains taken from scanning electron microstructure (SEM) images of cut surfaces were also examined. The results of a comparative study of the shrinkages and microstructure evolutions of the sintered samples under annealing in microwave heating systems and in an electric furnace were analyzed. A notably different behavior of the shrinkages and microstructures of alumina after being annealed was found. The results suggested that microwave radiations provided an additional force for mass transports. The results also indicated that the sintering process depended on microwave frequencies.

36 MATERIALS SCIENCE↗

Interfacial reactions and wetting in Al-Mg sintered by powder metallurgy process

Was conducted to analyze the effect of temperature variation on the bonding interface sintered composite Al-Mg and analyze the effect of variations of the density and hardness sinter. Research carried out by the base material powders of Al, Mg powder and solvent n-butanol. The method used in this study is a powder metallurgy, with a composition of 60% volume fraction of Al - 40% Mg. Al-Mg mixing with n-butanol for 1 hour at 500 rpm. Then the emphasis (cold comression) with a size of 1.4 cm in diameter dies and height of 2.8 cm, is pressed with a force of 20 MPa and held for 15 minutes. After the sample into pellets, then sintered at various temperatures 300 °C, 350 °C, 400 °C and 450 °C. Characterization is done by using the testing green density, sintered density, X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), vickers microhardness, and press test. XRD data analysis done by using X’Pert High Score Plus (HSP) to determine whether there is a new phase is formed. Test results show that the sintered density increasing sintering temperature, the resulting density is also increasing (shrinkage). However, at a temperature of 450 °C decreased (swelling). With the increased sinter density, interfacial bonding getting Kuta and more compact so that its hardness is also increased. From the test results of SEM / EDX, there Mg into Al in the border area. At temperatures of 300 °C, 350 °C, 400 °C, the phase formed is Al, Mg and MgO. While phase is formed at a temperature of 450 °C is aluminum magnesium (Al{sub 3}Mg{sub 2}), Aluminum Magnesium Zinc (AlMg{sub 2}Zn).

36 MATERIALS SCIENCE↗

Processing of Sintered Mo Disks Using Hydrogen Peroxide

Dissolution studies performed on NorthStar and ORNL disks show that an increase in sintering temperature has a negative effect on dissolution rates in 30% hydrogen peroxide. This is due to changes in the microstructure of sintered Mo powder. At higher sintering temperatures, the powder particles coalesce, form diffusion bonds, and grow into larger grains, which reduce the open porosity of the disks. The remaining porosity becomes trapped within the grains, and therefore the dissolution rates are very low. We also observed that different starting materials lead to different dissolution properties, and in some cases, even high sintering temperature at 1600°C does not produce disks with high packing densities. Studies with NorthStar disks showed that increased packing density can be achieved by increased pressing conditions without affecting the dissolution rates if mild sintering conditions are used. Future experiments will focus on producing sintered Mo disks produced from recovered Mo material and on optimizing the sintering process to produce disks with >90% packing density and good dissolution rates.

Dissolution↗

Microbial Biomarker Transition in High-Altitude Sinter Mounds From El Tatio (Chile) Through Different Stages of Hydrothermal Activity

Geothermal springs support microbial communities at elevated temperatures in an ecosystem with high preservation potential that makes them interesting analogs for early evolution of the biogeosphere. The El Tatio geysers field in the Atacama Desert has astrobiological relevance due to the unique occurrence of geothermal features with steep hydrothermal gradients in an otherwise high altitude, hyper-arid environment. We present here results of our multidisciplinary field and molecular study of biogeochemical evidence for habitability and preservation in silica sinter at El Tatio. We sampled three morphologically similar geyser mounds characterized by differences in water activity (i.e., episodic liquid water, steam, and inactive geyser lacking hydrothermal activity). Multiple approaches were employed to determine (past and present) biological signatures and dominant metabolism. Lipid biomarkers indicated relative abundance of thermophiles (dicarboxylic acids) and sulfate reducing bacteria (branched carboxylic acids) in the sinter collected from the liquid water mound; photosynthetic microorganisms such as cyanobacteria (alkanes and isoprenoids) in the steam sinter mound; and archaea (squalane and crocetane) as well as purple sulfur bacteria (cyclopropyl acids) in the dry sinter from the inactive geyser. The three sinter structures preserved biosignatures representative of primary (thermophilic) and secondary (including endoliths and environmental contaminants) microbial communities. Sequencing of environmental 16S rRNA genes and immuno-assays generally corroborated the lipid-based microbial identification. The multiplex immunoassays and the compound-specific isotopic analysis of carboxylic acids, alkanols, and alkanes indicated that the principal microbial pathway for carbon fixation in the three sinter mounds was through the Calvin cycle, with a relative larger contribution of the reductive acetyl-CoA pathway in the dry system. Other inferred metabolic traits varied from the liquid mound (iron and sulfur chemistry), to the steam mound (nitrogen cycle), to the dry mound (perchlorate reduction). The combined results revealed different stages of colonization that reflect differences in the lifetime of the mounds, where primary communities dominated the biosignatures preserved in sinters from the still active geysers (liquid and steam mounds), in contrast to the surviving metabolisms and microbial communities at the end of lifetime of the inactive geothermal mound.

Lipid biomarkers, geothermal springs, sinter, biog↗

Formation, structure, and thermal stability evolution of ternesite based on a single-stage sintering process

Highlights: • The synthesis of high-purity ternesite based on a single-stage sintering process was firstly studied. • The formation mechanism and crystallization behaviour of ternesite during sintering were investigated. • The structure perfection and symmetry of ternesite crystals were increased with its growth. • The growth and structural development of ternesite crystals during sintering resulted in a higher thermal stability of itself. Ternesite was prepared via a single-stage solid-state reaction from stoichiometric quantities of the CaCO{sub 3}, SiO{sub 2} and CaSO{sub 4}·2H{sub 2}O precursors. In this paper, the formation, structure, and thermal stability evolution of ternesite during sintering were investigated ex situ after quenching. The optimal sintering temperature for the formation of high-purity ternesite was approximately 1200 °C for 12 h, of which the purity level can reach as high as 96.3%. The results from scanning electron microscopy analysis suggest that the formation of ternesite benefited from the preformation of the intermediate silicate phase. Increasing the sintering temperature from 1100 °C to approximately 1250 °C was favourable for the growth of ternesite crystals, and a prolonged duration can also promote this behaviour. The structural perfection and symmetry of ternesite crystals increased with its growth, which was demonstrated by a multimethod approach. By means of thermal analysis, the growth and structural development of ternesite crystals during sintering eventually resulted in a higher thermal stability.

36 MATERIALS SCIENCE↗

Three-dimensional phase field sintering simulations accounting for the rigid-body motion of individual grains

Sintering is a widely used powder processing technique in industrial applications. During sintering, atoms migrate to decrease the energy of the system via two main mechanisms: coarsening and densification, both of which lead to significant morphological variation of the sintered microstructure. When simulating sintering dynamics, the phase-field method has been broadly utilized because of its convenience in tracking morphology evolution. When a large number of grains is involved, it is common to use the same order parameter to describe multiple grains that are not in direct contact with one another (in order to reduce the computational memory demands). However, with this treatment it is difficult to handle the rigid-body motion of individual grains during densification. In this work, an implementation scheme is introduced to overcome the challenge of calculating individual particle motion based on existing equations. It uses a grouping algorithm and sets a cutoff radius on each grain for calculating the particle velocity during densification. This method allows for the incorporation of the densification mechanism, which has been commonly ignored in previous work, into phase-field sintering models in three-dimensional simulations with a large number of particles/grains. Moreover, through combination with the smoothed boundary method, material properties of sintered microstructures, such as the effective diffusivity and Young’s modulus, can be calculated during the sintering processes.

36 MATERIALS SCIENCE↗

In situ formation of sintered cordierite–mullite nano–micro composites by utilizing of waste silica fume

Highlights: ► We succeeded to obtain in situ formed sintered cordierite–mullite nano–macro composites from waste and pure materials at 1400 °C. ► Their sinterability was greatly dependent on both firing temperature and composition. ► XRD patterns showed that the optimum temperature required for formation of sintered cordierite–mullite nano–macro composites was achieved at 1400 °C. ► The batch containing 70 wt.% cordierite and 30 wt.% mullite exhibited the best properties. ► Microstructures of the densified composites were composed of nano–macro cordierite–mullite structures. -- Abstract: This study aims at in situ formation of sintered cordierite–mullite nano–macro composites having high technological properties using waste silica fume, calcined ball clay, calcined alumina, and magnesia as starting materials. The starting materials were mixed in different ratios to obtain different cordierite–mullite composite batches in which the cordierite contents ranged from 50 to 100 wt.%. The batches were uni-axially pressed at 100 MPa and sintered at 1350, 1400 and 1450 °C to select the optimum temperature required for cordierite–mullite nano–macro composites formation. The formed phases were identified by X-ray diffraction (XRD) pattern. The sintering parameters in terms of bulk density (BD) and apparent porosity (AP) were determined. The microstructure of composites has been investigated by scanning electron microscope (SEM). Cold crushing strength (CCS) of the sintered batches was evaluated. The result revealed that the cordierite–mullite nano–macro composites were in-situ formed at 1400 °C. The batch containing 70 wt.% cordierite showed good physical and mechanical properties.

36 MATERIALS SCIENCE↗

Compensating for Sintering Distortion in Additively Manufactured Shaped Charge Liners using Physics-Informed Machine Learning

Copper is a challenging material to process using laser-based additive manufacturing due to its high reflectivity and high thermal conductivity. Sintering-based processes can produce solid copper parts without the processing challenges and defects associated with laser melting; however, sintering can also cause distortion in copper parts, especially those with thin walls. In this study, we use physics-informed Gaussian process regression to predict and compensate for sintering distortion in thin-walled copper parts produced using a Markforged Metal X bound powder extrusion (BPE) additive manufacturing system. Through experimental characterization and computational simulation of copper’s viscoelastic sintering behavior, we can predict sintering deformation. We can then manufacture, simulate, and test parts with various compensation scaling factors to inform Gaussian process regression and predict a compensated as-printed (pre-sintered) part geometry that produces the desired final (post-sintered) part.

36 MATERIALS SCIENCE↗

The effects of surface finish and grain size on the strength of sintered silicon carbide

The effects of surface treatment and microstructure, especially abnormal grain growth, on the strength of sintered SiC were studied. The surfaces of sintered SiC were treated with 400, 800 and 1200 grit diamond wheels. Grain growth was induced by increasing the sintering times at 2050 C. The beta to alpha transformation occurred during the sintering of beta-phase starting materials and was often accompanied by abnormal grain growth. The overall strength distributions were established using Weibull statistics. The strength of the sintered SiC is limited by extrinsic surface flaws in normal-sintered specimens. The finer the surface finish and grain size, the higher the strength. But the strength of abnormal sintering specimens is limited by the abnormally grown large tabular grains. The Weibull modulus increases with decreasing grain size and decreasing grit size for grinding.

You, Y. H.↗