Production of SiC particulate reinforced aluminium composites by melt spinning

Melt spinning is successfully used for the preparation of a rapidly solidified SiC particle reinforced AlSi7Mg0.3 alloy. The composites are prepared by introducing SiC particles in a semi-solid matrix slurry (SiC volume fractions up to 0.15, particle size 10 or 20 m). Duralcan material (SiC volume fraction 0.20, particle size 12 m) was also used. After stirring in the semi-solid state the composites are heated above the liquidus temperature and subsequently melt-spun. Featureless, columnar and dendritic zones can be identified in the ribbons. A finer dendritic structure is found around the SiC particles. The SiC particles tend to segregate to the air side of the ribbons and the segregation effect is influenced by particle size and volume fraction. As interface velocities are higher than the critical velocities predicted by models on interface pushing, it is concluded that fluid flow in the melt puddle is responsible for the segregation effect.     

Microstructures of in situ Al/TiB2 MMCs prepared by a casting route

In situ Al/TiB₂ metal matrix composites (MMCs) have been successfully produced by Salt-Metal reactions. This is a novel low-cost reactive approach, which involves adding Ti and B bearing salts to molten Al. The reactions between the salts lead to the formation of the reinforcing TiB₂ particles in the Al matrix. The in situ formed TiB₂ particles are very fine (below 1 m in size). Strings and clusters of particle agglomerates are distinct microstructural features of all the composites with pure Al as the matrix. The effects of processing parameters on the kinetics of TiB₂ formation and on the final microstructures are studied in detail. Besides, efforts are made to improve the distribution of TiB₂ particles in the Al matrix by means of chemical additions; it is found that a homogeneous distribution is obtained by using a eutectic Al-Si alloy as the matrix material.     

Synthesis and formation mechanism of submicrometre spherical cordierite powders by ultrasonic spray pyrolysis

Cordierite powders containing very pure submicrometre spherical particles have been synthesized by the ultrasonic spray pyrolysis. Aqueous solutions of silicic acid, Al(NO3)3·9H2O and MgCl2·6H2O were used as precursors. Scanning electron micrographs have shown that particle surfaces were smooth and the mean particle diameter was 0.834 m. For the estimation of chemical and phase composition and phase transformation temperatures, differential thermal analysis, thermogravimetric analysis, X-ray diffraction, energy dispersive spectroscopy and infrared analysis have been applied. It was found that during spray pyrolysis, the condensation of silicic acid mostly occurred while aluminium and magnesium ion remained incorported between Si–O–Si chains. By subsequent heating to over 800°C, Si–O–M bonds (M=Al, Mg) were formed. The synthesis of cordierite occurred by the crystallization of -cordierite from the amorphous phase at 900°C followed by the phase transformation of - into -cordierite in the temperature range 1100–1200°C.     

Formation of monodispersed Ta2O5 powders

The Ta₂O₅ powders synthesized by the hydrolysis of tantalum pentaethoxide, Ta(OC₂H₅)₅ in alcoholic solution were monodispersed fine oxide particles, which were a uniform, spherical shape, non-agglomerate, and had a narrow size distribution. They grew to 1.2m after ageing for 1 h after hydrolysis. Powder X-ray diffraction and differential thermal analysisthermogravimetric analysis showed the particles were amorphous and hydrated. These particles lost the water at 290° C and gave well-crystalline Ta₂O at 740° C. Throughout these thermal processes, the particle morphology was kept almost the same.     

The crack tip strain field of AISI 4340 Part I Measurement technique

This is the first paper in a study on the influence of the environment on the crack tip strain field for AISI 4340. A stressing stage for the environmental scanning electron microscope (ESEM) was constructed which was capable of applying loads up to 60 kN to fracture-mechanics samples. The measurement of the crack tip strain field required preparation (by electron lithography or chemical etching) of a system of reference points spaced at 5 m intervals on the sample surface, loading the sample inside an electron microscope, image processing procedures to measure the displacement at each reference point and calculation of the strain field. Two algorithms to calculate strain were evaluated. Possible sources of errors were calculation errors due to the algorithm, errors inherent in the image processing procedure and errors due to the limited precision of the displacement measurements. Estimation of the contribution of each source of error was performed. The technique allows measurement of the crack tip strain field over an area of 50×40 m with a strain precision better than ±0.02 at distances larger than 5 m from the crack tip.     

High pressure sintering of diamond-SiC composite

Sintered polycrystalline compacts in the system diamond-10–50 wt% SiC having average grain size of less than 1 m were prepared at pressure of 6 GPa and temperature between 1400 and 1600 °C. Knoop indentation hardness of the compacts increased with diamond content and sintering temperature, and specimens with a Knoop indentation hardness greater 40 GPa were obtained. It was found that small amount of Al addition into the starting diamond-SiC powder was effective to improve relative density and Knoop indentation hardness of the compacts. The formation of graphite was also suppressed by the addition of Al. Microstructure observation by SEM and TEM suggested that Al segregated at the grain boundary and promoted the bonding between grains. Thin microtwins were observed in diamond grains, whereas fine wavy structures with slightly different orientations were observed in SiC grains, with or without Al addition.     

Ultrasonic spray pyrolysis for nanoparticles synthesis

This article presents new findings regarding the effects of precursor drop size and precursor concentration on product particle size and morphology in ultrasonic spray pyrolysis. Large precursor drops (diameter > 30 m) generated by ultrasonic atomization at 120 kHz yielded particles with holes due to high solvent evaporation rate, as predicted by the conventional one particle per drop mechanism. Precursor drops 6–9 m in diameter, generated by an ultrasonic nebulizer at 1.65 MHz and 23.5 W electric drive power, yielded uniform spherical particles 90 nm in diameter with proper control of precursor concentration and residence time. Moreover, air-assisted ultrasonic spray pyrolysis at 120 kHz and 2.3 W yielded spherical particles about 70% of which were smaller than those produced by the ultrasonic spray pyrolysis of the 6–9 m precursor drops, despite much larger precursor drop size (28 m peak diameter versus 7 m mean diameter). These particles are much smaller than predicted by the conventional one particle per drop mechanism, suggesting that a gas-to-particle conversion mechanism may also be involved in spray pyrolysis.     

Processing, microstructure and mechanical properties of hot-pressed SiC continuous fibre/SiC composites

SiC (SCS-6TM) continuous fibre/SiC composites were fabricated by hot-pressing at 1700°C in vacuum using an Al sintering additive. Analytical transmission electron microscopy was used to investigate the microstructure of the composites. The room-temperature mechanical and high-temperature creep properties of the composites were investigated by four-point bending. The SiC powders used were sintered at a relatively low sintering temperature to high density (97% of theoretical density) with the addition of the Al sintering additive. It is believed that the Al additive is very efficient for the densification of SiC. The SiC fibres maintained their original form and microstructure during fabrication. The SiC matrix reacted with the outermost carbon sublayer in the fibre, forming a thin (1.8–4.8m) interfacial layer, which was composed of Al4C3, Si–Al–C, and Si–Al–O phases. The incorporation of SiC fibre into a dense SiC matrix significantly increased the room-temperature failure strain and improved the high-temperature creep properties. In addition, the incorporation of SiC fibre into a porous SiC matrix increased the room-temperature failure strain, but did not contribute to the high-temperature creep properties.     

Effect of structure of interfacial coating layer on mechanical properties of continuous fiber reinforced reaction sintered silicon carbide matrix composite

A dense silicon carbide matrix composite reinforced by Hi-Nicalon fibers CVD coated with boron nitride and silicon carbide was fabricated by slurry impregnation and subsequent reaction sintering with molten silicon. The effect of the structure and the thickness of the silicon carbide layer of the fiber coating on the mechanical properties of the composite were investigated. That is, three types of silicon carbide layers, namely a dense structure with a thickness of 0.15 m and two porous structures with a thickness of 0.15 m and 0.48 m, respectively, were investigated. As a result, excellent strength property of ceramic matrix composite (CMC) was obtained in the case of the dense silicon carbide (SiC) layer. The thickness effect of the SiC layer on the strength was smaller than that of the structure.     

Particle distribution control in cast aluminium alloy-mica composites

A suspension of mica particles (40m diameter and 3.7 thick) obtained in a mechanically stirred Al-4 wt % Cu-1.5 wt % Mg melt was poured and solidified in a variety of moulds under different heat flow configurations. The resulting cast structure showed a non-uniform distribution of dispersed mica particles with mica-depleted and segregated zones due to their flotation before and during solidification. The experimentally observed profiles of mica-free regions deviate significantly from those computed on the basis of Stokes's law and freezing-time computations. In relatively thick castings, segregation of mica could be minimized by using low pouring temperatures and/or side as well as bottom chilling. It was found, however, that thin castings (12.5 mm) could easily be produced with a homogeneous distribution of mica particles.     

Production of rapidly solidified Al/SiC composites

Rapidly solidified metal matrix composites have been produced on a laboratory scale either by (1) melt spinning a composite after introduction of the ceramic phase and extrusion of the flakes obtained, or (2) blending melt-spun powder (basic alloy) with the ceramic phase and subsequent extrusion. AlMg(Si) alloys were used as matrix material while SiC particles with diameters of 3 or 20 m were used as the ceramic phase. For the composites prepared by route 1 it was found that the basic alloy was reinforced by the addition of 3 m particles whereas for the 20m particles reinforcement was observed only for very ductile matrices. The bond between SiC particles and matrix was good. A diffusion and wetting bond was formed. For the composites prepared by route 2 it was found that reinforcement did not occur and that the bond between particles and matrix was weak. Debonding of the particles took place in the case of tensile fracture. The advantage of a rapidly solidified matrix for these composites is that relatively high ductilities are combined with good reinforcement effects. Prior contact of the ceramic phase and the aluminium melt is needed for a good bond between SiC and the matrix material. It is concluded that route 1 should be preferred for the production of rapidly solidified aluminium matrix composites.     

Physicochemical Study of the Mechanism of Radionuclide Migration from the Shelter Object and Its Service Area to Groundwater

Radionuclide distribution over coarsely dispersed particles (>0.1 m), colloidal particles (0.01-0.1 m), and ionic species in water taken from the Shelter Object and in groundwater sampled from observation wells situated in the service area was studied. A new mechanism of radionuclide transfer from the soil surface to groundwater was suggested.     

Manufacturing and friction welding properties of particulate reinforced 7005 Al

This study has successfully incorporated Al₂O₃, SiC particulates into the 7005Al alloy matrix by using a drag-push method. The reinforced particulates are uniformly distributed in the matrix. This study also discusses the influence of aging treatment on the friction welding properties of 7005Al/10 wt%, 15 m and 6 m SiC_(p) composites and 7005Al/10 wt%, 15 m Al₂O_3(p) composites joint system. Experimental results show that after peak aging treatment was performed, if SiC particulates were used in the strengthening phase, the heat-affected zone (HAZ) had higher density of strengthening particulate, this resulted an increase in the hardness and stress concentration at the fully plasticized zone (Zpl) of the HAZ region, but a decrease in the width of the Zpl zone and the welding strength. And the welded fracture surface morphology had a low-ductile fracture.     

Submicron diameter nickel filaments and their polymer-matrix composites

Discontinuous nickel filaments of diameter 0.4 m and having a carbon core of diameter 0.1 m were fabricated by electroplating nickel on discontinuous carbon filaments. They exhibited a grain size of 0.016 m and electrical resistivity of about 5 × 10^–6 ·cm. In an amount as low as 7 vol.% in a polymer (polyether sulfone) matrix, they resulted in a composite exhibiting electromagnetic interference shielding effectiveness of 87 dB and reflection coefficient 0.95 at 1–2 GHz, tensile strength 52 MPa, tensile ductility 1.0%, and density 1.87 g/cm³.     

Absolute frequency measurements of lasers in submillimeter and infrared ranges

Conclusion The investigations into lasers constructed in the submillimeter and infrared regions showed satisfactory results for their use in absolute frequency measurements. The fast-response nonlinear elements — W=Si and W=Ni point diodes — have been tested in the multiplier-mixer mode from 337 to 10 exclusively. The frequencies have been measured of the molecular lasers HCN (=337 ), D₂O (=84 ), H₂O (=28 ) and the P(14) CO₂ (=10.53 ) and R(30) (=10.18 ) lines. The measurement error of 5·10^–7 was determined by the indeterminacies of fixing the peak of the laser generation lines. An increase of the measurement accuracy will be achieved by the mutual tying in of the laser frequencies to one another.Translated from Izmeritel'naya Tekhnika, No. 10, pp. 59–61, October, 1976.     

Spherical particle preparation of Na+-ion conductive Na4Zr2Si3O12 by mist pyrolysis

Spherical polycrystalline particles of Na₄Zr₂Si₃O₁₂ (NZS) have been prepared by a mist pyrolysis technique with alkoxide ethanol solution. Firing the precursor particles, obtained by pyrolysing at 550 °C, yielded the NZS with the highest S/N ratio and the least second phase at 1000 °C. Each spherical particle with an average size of 0.5 m was composed of primary particles of 0.1 m diameter after firing. Comparing the particle formation process with the sol-gel, alkoxide pyrolysis and the aqueous solution processes, it would appear that the primary particle size of the mist-pyrolysed NZS depends on the size and residual alkyl group content of the precursor polymers.     

Effect of grain size upon flow and fracture in a precipitation-strengthened Ti-8 wt % Al-0.25 wt % Si alloy

The interaction of grain size and precipitation strengthening has been studied in a Ti-8 wt % Al-0.25 wt %Si alloy. Grain sizes varying from 9 to 90m were produced by warm-working and annealing the alloy in the single--phase field. A uniform distribution of the coherent ₂ particles in the matrix was produced by ageing the alloy in the two-phase ( + ₂) field. The yield strength Hall-Petch slopes of the alloys with and without the ₂ precipitates were found to be nearly equal, indicating that the precipitation and grain-boundary strengthening are linearly additive. While specimens containing no precipitates exhibited a high ductility for all grain sizes, the ductility of the specimens with the ₂ particles decreased drastically with increasing grain size. TEM examination of the specimens containing the precipitates revealed a highly planar, localized slip and SEM examination of the fracture surfaces of these specimens revealed a transition in fracture behaviour from highly dimpled to mixed cleavage and intergranular with increasing grain size.     

Stereolithography of structural complex ceramic parts

A cost-effective method of complex ceramic parts manufacturing using stereolithography has been developed. The process consists in fabricating ceramic pieces by laser polymerization of an UV curable monomeric system, subsequent removal of organic components and sintering. Highly concentrated suspensions of well dispersed ceramic particles (up to 60 vol%) in a reactive acrylic monomer, with a suitable rheological behaviour for the spreading of thin layers (down to 25 m) were defined. Adequate cured depth (higher than 200 m) is obtained even at high scanning speeds. Nevertheless, a compromise has to be found between the cured depth and the cured width to improve the dimensional resolution. The dimensional resolution reached on alumina partterns is about 200 m with an energy density of 0.05 J · cm^–2.     

SiC filament/titanium matrix composites regarded as model composites

Two types of large diameter SiC CVD filaments have been investigated on both chemical and mechanical standpoints: a 100m filament with a tungsten core (from SNPE) and three 140m filaments with carbon cores and surface coatings (from AVCO). On the basis of microprobe (X-ray, Auger and Raman), X-ray diffraction and SEM analyses, it appears that the former is made of a single homogeneous stoichiometric SiC deposit while the latter are mainly made of two concentric shells (the inner being a SiC+C mixture and the outer almost pure SiC). All the C-core filaments had received a surface coating (either pure pyrocarbon or SiC+C mixture) presumably to protect the brittle SiC deposit against abrasion due to handling in opposition to the W-core filament which seems to have no surface coating at all. The W-core filament, although smaller in diameter, is weaker than the C-core filaments (average UTS of 3 and 4 GPa respectively for a 40 mm gauge length). However, its strength distribution is much narrower (Weibull moduli of 7–8 and 2–5 respectively). Failures of most filaments appear to have a multimodal character.     

Formation of zirconium titanate powder from a sol-gel prepared reactive precursor

A hydroxoperoxo compound of Zr and Ti (HXPZT) was prepared as a reactive powder by a sol-gel method. X-ray diffraction and SEM studies showed it to be formed from small (ca. 10–15 m) amorphous particles. The effects of progressive thermal treatment were determined by differential thermal analysis, thermogravimetric analysis, temperature programmed desorption, X-ray diffraction, energy-dispersive spectrometry and SEM. The features observed have been attributed to the removal of physically and chemically bonded water and of some nitrogen-containing compound. Crystallization of zirconium titanate occurs at low temperature (650 °C), giving rise to spherical (ca. 2 m dia.) regular particles.