Mechanical and corrosion properties of full liquid phase sintered WE43 magnesium alloy specimens fabricated via binder jetting additive manufacturing

This study investigates full liquid phase sintering as a process of fabrication parts from WE43(Mg-4wt.%Y-3wt.%RE-0.7wt.%Zr)alloy using binder jetting additive manufacturing(BJAM).This fabrication process is being developed for use in producing structural or biomedical devices.Specifically,this study focused on achieving a near-dense microstructure with WE43 Mg alloy while substantially reducing the duration of sintering post-processing after BJAM part rendering.The optimal process resulted in microstructure with 2.5%porosity and significantly reduced sintering time.The improved sintering can be explained by the presence of Y_(2)O_(3)and Nd_(2)O_(3)oxide layers,which form spontaneously on the surface of WE43 powder used in BJAM.These layers appear to be crucial in preventing shape distortion of the resulting samples and in enabling the development of sintering necks,particularly under sintering conditions exceeding the liquidus temperature of WE43 alloy.Sintered WE43 specimens rendered by BJAM achieved significant improvement in both corrosion resistance and mechanical properties through reduced porosity levels related to the sintering time.

Mineral-phase evolution and sintering behavior of MO–SiO_2–Al_2O_3–B_2O_3 (M = Ca,Ba) glass-ceramics by low-temperature liquid-phase sintering

In this work, network former SiO_2 and network intermediate Al_2O_3 were introduced into typical low-melting binary compositions CaO·B_2O_3, CaO·2B_2O_3, and BaO·B_2O_3 via an aqueous solid-state suspension milling route. Accordingly, multiple-phase aluminosilicate glass-ceramics were directly obtained via liquid-phase sintering at temperatures below 950°C. On the basis of liquid-phase sintering theory, mineral-phase evolutions and glass-phase formations were systematically investigated in a wide MO–SiO_2–Al_2O_3–B_2O_3(M = Ca, Ba) composition range. The results indicate that major mineral phases of the aluminosilicate glass-ceramics are Al_(20)B_4O_(36), CaAl_2Si_2O_8, and BaAl_2Si_2O_8 and that the glass-ceramic materials are characterized by dense microstructures and excellent dielectric properties.

Kinetic characteristics of liquid phase sintering of mechanically activated W-15wt%Cu powder

The kinetic characteristics of W grain growth operated by diffusion controlled Oswald ripening （DOR） during liquid phase sintering were studied. A liquid phase sintering of W-15wt%Cu was carried out by pushing compacts into a furnace at the moment when the temperature increased to 1340℃ for different sintering times. The results show that liquid phase sintering produces the compacts with considerably low relative density and inversely, rather high homogeneity. On the basis of the data extracted from the SEM images, the kinetic equation of W grain growth, G^n = G0^n ＋ kt, is determined in which the grain growth exponent n is 3 and the grain growth rate constant k is 0.15 μm^3/s. The cumulative normalized grain size distributions produced by different sintering times show self-similar. The cumulative distribution function is extracted from the curves by non-linear fitting. In addition, the sintering kinetic characteristics of W-15wt%Cu compacts were also investigated.

Influence of gangue existing states in iron ores on the formation and flow of liquid phase during sintering

Gangue existing states largely affect the high-temperature characteristics of iron ores. Using a micro-sintering method and scan- ning electron microscopy, the effects of gangue content, gangue type, and gangue size on the assimilation characteristics and fluidity of liquid phase of five different iron ores were analyzed in this study. Next, the mechanism based on the reaction between gangues and sintering mate- dais was unraveled. The results show that, as the SiO2 levels increase in the iron ores, the lowest assimilation temperature （LAT） decreases, whereas the index of fluidity of liquid phase （IFL） increases. Below 1.5wt%, Al2O3 benefits the assimilation reaction, but higher concentra- tions proved detrimental. Larger quartz particles increase the SiO2 levels at the local reaction interface between the iron ore and CaO, thereby reducing the LAT. Quartz-gibbsite is more conductive to assimilation than kaolin. Quartz-gibbsite and kaolin gangues encourage the forma- tion of liquid-phase low-Al2O3-SFCA with high IFL and high-Al2O3-SFCA with low IFL, respectively.

MANUFACTURING OF ALUMINUM/FLY ASH COMPOSITE WITH LIQUID REACTIVE SINTERING TECHNOLOGY

The Al/fly ash composites are fabricated by liquid reactive sintering P/M process with fly ash particles as intensifying phases. The reactivity and newly formed phases during liquid sintering process have been analyzed by combing Thermochemicdl data base calculation and XRD characterization. The results show that some of constituents in fly ash have reacted with liquid aluminum so that the elemental Si, Fe, Ti as well as some amount of intermetallic compounds occur. The properties of aluminum/fly ash composites have been improved. With the fraction of fly ash increase, the composite density decreases; the hardness and the modulus of the composite increases, and the composite wear resistance are significantly increased. The fly ash reinforced composites represent a sort of low cost product with possible widespread applications in the automotive, small engine, and electromechanical machinery sectors.

Liquid Phase Sintering (LPS) and Dielectric Constant of α-Silicon Nitride Ceramic

The spark plasma sintering （SPS） was applied to prepare α-Si3 N4 ceramics of different densities with magnesia, silicon dioxide, alumina as the sintering aids. The mechanism of liquid phase sintering （LPS） wus discussed and the factors influencing the density of the prepared samples were analyzed. The dielectric constant of sintered samples was tested. The experimental results show that the density can be controlled from 2.48 g/ cm^3 to 3.09 g/ cm^3 while the content of the sintering aids and the sintering temperature alter and the dielectric constant is closely dependent on the density of obtained samples.

Microstructure and properties of liquid-phase sintered tungsten heavy alloys by using ultra-fine tungsten powders

The microstructure and properties of liquid-phase sintered 93W-4.9Ni-2.1Fe tungsten heavy alloys using ultra-fine tungsten powders (medium particle size of 700 nm) and original tungsten powders (medium particle size of 3 μm) were investigated respectively. Commercial tungsten powders (original tungsten powders) were mechanically milled in a high-energy attritor mill for 35 h. Ultra-fine tungsten powders and commercial Ni, Fe powders were consolidated into green compacts by using CIP method and liquid-phase sintering at 1 465 ℃ for 30 min in the dissociated ammonia atmosphere. Liquid-phase sintered tungsten heavy alloys using ultra-fine tungsten powders exhibit full densification (above 99% in relative density) and higher strength and elongation compared with conventional liquid-phase sintered alloys using original tungsten powders due to lower sintering temperature at 1 465 ℃ and short sintering time. The mechanical properties of sintered tungsten heavy alloy are found to be mainly dependent on the particles size of raw tungsten powders and liquid-phase sintering temperature.

Effect of Additives on the Sintering of Amorphous Nano-sized Silicon Nitride Powders

Amorphous nano-sized silicon nitride powders were sintered by liquid phase sintering. The influences of the additives of Y2O3 and Al2O3 prepared by two different ways, the polyacrylamide gel method and the precipitation method, were investigated. The grain sizes of the additives prepared by the first method were finer than those of prepared by the latter method. When sintered at the same temperature, 1700 ℃, the average grain size of the silicon nitride is 0.3 um for the sample with the former additives, which is much finer than the one with the latter additives. The density of additives prepared by precipitation method is clearly lower than those of prepared by polyacrylamide gel method.

Directional migration behavior of cerium during sintering process of mischmetal doped cemented carbide

Three observation methods were used to investigate the existing form and the behavior of rare earth during the sintering process of high activity mischmetal （RE, with lanthanum and cerium） doped WC-8%Co-0.048%RE（mass fraction） alloy with low carbon-containing level by scanning electron microscopy （SEM） and energy dispersive X-ray spectroscopy （EDXS）, considering the fact that the addition amount of rare earth in the alloy is very minute. The directional migration process and mechanism of cerium were discussed. First, the sinter skin （surface） is observed. oxide on the sinter skin, and lanthanum in these cerium observed, and lanthanum containing phase/micro-zone in It is shown that there exists a dispersedly distributed cerium containing enrichment positions is very minute. Secondly, the polished section is the alloy is identified. Finally, based on the fact that the fracture of cemented carbide is resulted from the heterogeneous phase or other defects within the microstructure, the fracture surface is observed and cerium containing phase/micro-zone in the fracture source approximately 260 μm from the surface is identified. These combined observations reveal adequately the fact that lanthanum and cerium get separated and cerium predominantly migrates towards the surface during the sintering process.

Effect of Mg composition on sintering behaviors and mechanical properties of Al-Cu-Mg alloy

Al-3Cu-Mg alloy was fabricated by the powder metallurgy(P/M) processes. Air-atomized powders of each alloying element were blended with various Mg contents(0.5%, 1.5%, and 2.5%, mass fraction). The compaction pressure was selected to achieve the elastic deformation, local plastic deformation, and plastic deformation of powders, respectively, and the sintering temperatures for each composition were determined, where the liquid phase sintering of Cu is dominant. The microstructural analysis of sintered materials was performed using optical microscope(OM) and scanning electron microscope(SEM) to investigate the sintering behaviors and fracture characteristics. The transverse rupture strength(TRS) of sintered materials decreased with greater Mg content(Al-3Cu-2.5Mg). However, Al-3Cu-0.5Mg alloy exhibited moderate TRS but higher specific strength than Al-3Cu without Mg addition.

Microstructural evolution during direct laser sintering of multi-component Cu-based metal powder

A multi-component Cu-based metal powder was chosen for direct laser sintering. The powder consists of a mixture of high-purity Cu powder, pre-alloyed CuSn and CuP powder. Liquid phase sintering with complete melting of the binder (CuSn) but non-melting of the cores of structural metal (Cu) proves to be a feasible mechanism for laser sintering of this powder system. The microstructural evolution of the sintered powder with variation of laser processing parameters was presented. High sintering activities and sound densification response were obtained by optimizing the laser powers and scan speeds. Using a high laser power accompanied by a high scan speed gives rise to balling effect. At a high laser power with a slow scan speed the sintering mechanism may change into complete melting/solidification, which decreases the obtainable sintered density. The role of additive phosphorus in the laser sintering process is addressed. Phosphorus can act as a fluxing agent and has a preferential reaction with oxygen to form phosphatic slag, protecting the Cu particles from oxidation. The phosphatic slag shows a concentration along grain boundaries due to its light mass as well as the short thermal cycle of SLS.

SINTERING BEHAVIOR OF Cu-Al ALLOY POWDER

The dynamic behaviour of transient liquid phase during sintering 5wt% Al-Cu alloy compacts with green density of 7.56g/cn￣3 is observed by means of high temperature metallographic microscopy. The structures and precipitating order of the phases are identified by means of DTA, TEM and composion analysis at the definite point and phase diagram. The results show that little Al-rich liquid phase resulting from eutectic reaction flows into the capillaries in Cu powder, because the peritectic reactions exhausts the liquid in high density compact,the composition homogenization needs longer sintering time. The remainder γ2-phase is discovered at place of the neck of sintered Cu particle and has a crystallographic relationship of (111)_(Cu)∥(033)_γ_2 after alloy is sintered at 900 ℃for 3h.

One step sintering of homogenized bauxite raw material and kinetic study

A one-step sintering process of bauxite raw material from direct mining was completed, and the kinetics of this process was analyzed thoroughly. The results show that the sintering kinetics of bauxite raw material exhibits the liquid-phase sintering behavior. A small portion of impurities existed in the raw material act as a liquid phase. After X-ray diffraction analyses, scanning electron microscopy observations, and kinetics calculations, sintering temperature and heating duration were determined as the two major factors contributing to the sintering process and densification of bauxite ore. An elevated heating temperature and longer duration favor the densification process. The major obstacle for the densification of bauxite material is attributed to the formation of the enclosed blowhole during liquid-phase sintering.

多元(U,Zr, Nb)C燃料制备技术与性能机理研究

多元(U,Zr, Nb)C燃料因具有熔点高、热导率高、低裂变气体释放率及优异的高温力学性能等优点,是目前大功率空间核推进反应堆选用燃料之一。本文采用碳热还原和液相烧结相结合的粉末冶金工艺制备多元(U,Zr, Nb)C燃料芯块,研究了工艺参数对烧结芯块反应动力学、相结构、导热性能和微观结构的作用机制和影响规律。结果表明:在1 800℃、50 MPa和1 h的烧结条件下,通过添加0.5%金属铀形成的液相烧结工艺制备得到芯块密度可达95.5%TD;当原料M/C(M为金属元素总量)摩尔比为1∶6.5时,可制备得到M/C比为1的正化学计量碳化物燃料;(U0.2,Zr, Nb)C的晶格常数比(U0.1,Zr, Nb)C的晶格常数略高;多元(U,Zr, Nb)C碳化物燃料芯块热导率与相成分、密度和温度均有关;芯块气孔分布较均匀,没有联通的开气孔存在,气孔尺寸在1~3μm。

烧结熔剂对钒钛磁铁矿液相高温行为的影响

为了改善钒钛磁铁矿的烧结液相行为,采用微型烧结方法研究了不同熔剂对钒钛磁铁矿液相高温行为的影响.结果表明:从钒钛磁铁矿的液相高温行为考虑,白云石适合做低钛型钒钛矿的烧结熔剂,石灰石适合做低钛型或中钛型钒钛矿的烧结熔剂;与高钛型钒钛矿相匹配的熔剂为高活性的生石灰,菱镁石并不适合做钒钛矿的烧结熔剂.因此,优化钒钛磁铁矿的液相高温行为应根据矿石中的钛含量,调节烧结熔剂中石灰石和高活性生石灰的配比,以及不同性能石灰石和高活性生石灰的使用量.

莫来石纤维增强氧化物多孔陶瓷及其性能研究

以不同规格的粉煤灰漂珠、长石粉和铝矾土粉为主要原料,引入莫来石纤维为增强相,研究莫来石纤维含量对多孔陶瓷材料性能的影响规律及作用机理。结果表明:高温下长石粉中的低熔相能够降低材料的共晶熔点,将基质间的物理界面结合转变为化学结合。样品经1100℃烧成后,随着莫来石纤维含量的增加,多孔陶瓷的闭口气孔率增加,而常温耐压强度和体积密度呈现先增大后减小的趋势。当莫来石纤维含量为10 wt.%时,材料具有最佳综合性能,其体积密度为(0.74±0.01)g·cm^(−3)、真气孔率为(72.70±0.58)%,常温下耐压强度为(7.30±0.64)MPa。此外,试样在300℃、600℃及900℃下的平均热导率分别为0.202 W·m^(−1)·K^(−1)、0.214 W·m^(−1)·K^(−1)及0.244 W·m^(−1)·K^(−1)。

氮化硅陶瓷低温烧结助剂研究进展

氮化硅陶瓷性能优异,然而由于其共价键较强,自扩散系数小,烧结难度较大。目前高性能氮化硅陶瓷主要通过高温气压烧结法制备,烧结温度在1800℃以上,对设备要求较高,制备成本也较高,限制了氮化硅陶瓷的实际应用。低温烧结作为降低氮化硅生产成本的有效途径之一,受到了业界广泛关注。目前国内外关于氮化硅陶瓷低温烧结的研究主要集中在烧结助剂的选择方面,烧结助剂可以分为两类:使用与SiO_(2)共晶温度较低的烧结助剂和使用多组分烧结助剂。综述了这两类低温烧结助剂的研究进展,并提出了低温烧结助剂选择的合理方案。综合来看,要在低温下制得性能良好的氮化硅陶瓷,需选用与SiO_(2)具有低共晶点的烧结助剂,并配合使用多元组分调控氮化硅陶瓷的微观结构和性能。

以非氧化物为烧结助剂制备高导热氮化硅陶瓷的研究进展

功率半导体器件高电压、大电流、高功率密度的发展趋势,对器件中陶瓷基板的散热能力和可靠性提出了更高的要求,兼具高热导率和优异力学性能的氮化硅陶瓷作为功率半导体器件的首选散热基板材料受到了广泛关注。目前氮化硅陶瓷热导率的实验值与理论值存在较大差距,高温、长时间保温的制备条件不仅会使晶粒过分长大,削弱其力学性能,而且会造成成本高企,限制了其规模化应用。晶格氧缺陷是影响氮化硅陶瓷热导率的主要因素,通过筛选非氧化物烧结助剂降低体系中的氧含量,调节液相的组成和性质并构建“富氮-缺氧”的液相,调控液相中的溶解析出过程,促进氮化硅陶瓷晶格氧的移除及双峰形貌的充分发育,从而实现氮化硅陶瓷热导率-力学性能的协同优化是目前研究的热点。本文基于元素分类综述了当前国内外开发的非氧化物烧结助剂体系,着重从液相调节和微观形貌调控的角度介绍了非氧化物烧结助剂改善氮化硅陶瓷热导率的作用机理,分析了晶粒发育、形貌演变规律和晶格氧移除机制,并展望了高导热氮化硅陶瓷的未来发展前景。

微多孔铜表面参数对自驱射流强化池沸腾的影响

为强化池沸腾性能,本文基于一种适用于实际池沸腾强化的自驱射流冲击装置,使用R1336mzz(Z)作为工质,微多孔铜表面为加热表面,实验研究了自驱射流装置对沸腾性能的影响,并参数化研究了微多孔表面制备特征对池沸腾性能的影响,如烧结过程中的铜粉粒径尺寸(43µm、66µm、101µm)以及微多孔层厚度与粒径尺寸之比(4、6、10)。研究结果表明,自驱射流装置的置入确保了液体对表面的持续供给以及促进了气泡的脱离,从而有效增强了微多孔铜表面的临界热流密度(CHF)。然而,自驱射流的存在会对沸腾产生抑制作用,从而造成换热性能的轻微恶化,且抑制程度强弱与铜粉粒径尺寸大小呈正相关、与厚度与粒径之比大小呈负相关。参数化研究结果显示,沸腾换热性能随粒径增大而增大、随厚度与粒径之比增大先增大后降低。微多孔铜表面吸液能力均随铜粉粒径以及厚度与粒径之比的增加而提升,并且大部分情形下,搭配自驱射流装置与否,均不会影响其与CHF的线性正相关。但是,当粒径尺寸为101µm时,自驱射流装置会放大其过小的毛细力所带来的润湿劣势,进而造成CHF的偏低。与非微多孔铜表面的标准池沸腾性能相比,本研究的CHF和hNB@CHF提升幅度分别可达189.2%和337.5%,最佳为CHF=72.0W/cm^(2)和hNB@CHF=87.5kW/(m^(2)·K)。

MgF_(2)助剂对MgAl_(1.9)Ga_(0.1)O_(4)透明陶瓷的制备与光学性能的影响

MgAl_(1.9)Ga_(0.1)O_(4)透明陶瓷具有优异的光学性能,其制备依赖于高质量坯体的凝胶注模成型和长时间的无压预烧。本研究选择MgF_(2)为烧结助剂,并通过瞬时液相调节无压预烧的致密化过程。采用干压成型、无压预烧和热等静压烧结制备了不同尺寸的MgAl_(1.9)Ga_(0.1)O_(4)透明陶瓷样品,并系统分析了MgF_(2)对材料显微结构、光学和机械性能的影响。研究表明:MgF_(2)在~1230℃熔化形成的液相促使陶瓷的致密度与晶粒尺寸增大,后续烧结过程中残留的MgF_(2)氧化为MgO并固溶进入MgAl_(1.9)Ga_(0.1)O_(4)晶格。添加质量分数0.2%MgF_(2)的2.04 mm厚透明陶瓷样品在紫外和可见光区域具有76.5%~83.4%的直线透过率和较高的光学质量。此外,该陶瓷的特征抗弯强度为167.1 MPa,与细晶MgAl2O4透明陶瓷相近,但是前者的Weibull模数(8.81±0.29)更高。本研究为制备光学性能良好的大尺寸MgAl_(1.9)Ga_(0.1)O_(4)透明陶瓷提供了新的选择。