Processing TiAl-Based Alloy by Elemental Powder Metallurgy

TiAI-based alloys with various compositions (including Ti-48Al, Ti-47Al-2Cr-2Nb, Ti-47Al-2Cr-2Nb-0.2B and Ti-47Al-3Cr, in mole fraction) had been prepared by elemental powder metallurgy (EPM). The results have shown that the density of the prepared Ti-48AI alloy increases with increasing hot pressing temperature up to 1300℃. The Ti-48AI alloy microstructure mainly consisted of island-like Ti3Al phase and TiAl matrix at hot pressing temperature below 1300℃, however, coarse α2/γ lamellar colonies and γ grains appeared at 1400℃. It has also indicated that the additions of elemental Cr and B can refine the alloy microstructure. The main microstructural inhomogeneity in EPM TiAI-based alloys was the island-like α2 phase or the aggregate of α2/γ lamellar colony, and such island-like structure will be inherited during subsequent heat treatment in (α＋γ) field. Only after heat treatment in a field would this structure be eliminated. The mechanical properties of EPM TiAl-based alloys with various compositions were tested, and the effect of alloy elements on the mechanical properties was closely related to that of alloy elements on the alloy microstructures. Based on the above results, TiAI-based alloy exhaust valves were fabricated by elemental powder metallurgy and diffusion joining. The automobile engine test had demonstrated that the performance of the manufactured valves was very promising for engine service.

Simulation Research on the Effect of Spreading Process Parameters on the Quality of Lunar Regolith Powder Bed in Additive Manufacturing

Lunar surface additive manufacturing with lunar regolith is a key step in in-situ resource utilization.The powder spreading process is the key process,which has a major impact on the quality of the powder bed and the precision of molded parts.In this study,the discrete element method(DEM)was adopted to simulate the powder spreading process with a roller.The three powder bed quality indicators,including the molding layer offset,voidage fraction,and surface roughness,were established.Besides,the influence of the three process parameters,which are roller’s translational speed,rotational speed,and powder spreading layer thickness on the powder bed quality indicators was also analyzed.The results show that with the reduction of the powder spreading layer thickness and the increase of the rotational speed,the offset increased significantly;when the translational speed increased,the offset first increased and then decreased,which resulted in an extreme value;with the increase of the layer thickness and the decrease of the translational speed,the values for voidage fraction and surface roughness significantly reduced.The powder bed quality indicators were adopted as the optimization objective,and the multi-objective parameter optimization was carried out.The predicted optimal powder spreading parameters and powder bed quality indicators were then obtained.Moreover,the optimal values were then verified.This study can provide informative guidance for in-situ manufacturing at the moon in future deep space exploration missions.

Dispersion of multiwalled carbon nanotubes in aluminum powders

Multiwalled carbon nanotubes (MWNTs) were treated with the reflux within the concentrated nitric acid for 0-25 h to purify and disperse the tangled MWNTs. The effect of reflux time on the morphology and the weight loss of MWNTs were investigated. Meanwhile,the dispersion of MWNTs with 0-2.0 wt.% in 2024Al powders using mechanical stirring with an assisting ultrasonic shaker in ethanol was also studied. The results show that the reflux time markedly affects the morphology of MWNTs. The weight loss of MWNTs increases as the reflux time increases. When the content of MWNTs is less than 1.0 wt.%,MWNTs can uniformly distribute on the surface of 2024Al powders; however,when the content of MWNTs is 2.0 wt.%,MWNTs entangle with each other on the surface of 2024Al powders.

THE STRUCTURE CONTROL OF ALUMINUM FOAMS PRODUCED BY POWDER COMPACTED FOAMING PROCESS

A new technique, powder compact foaming process for the production of aluminumfoams has been studied in this article. According to this method, the aluminum pow-der is mixed with a powder foaming agent (TiH_2). Subsequent to mixing, the powderblend is hot compacted to obtain a dense semi--finished product. Upon heating to tem-peratures within the range of the melting point, the foaming agent decomposes to evolvegas and the semi--finished product expands into a porous cellular aluminum. Foamingprocess is the key in this method. Based on experiments, the foaming characteris-tics were mainly analyzed and discussed. Experiments show that the aluminum--foamwith closed pores and a uniform cell structure of high porosity can be obtained usingthis method by adjusting the foaming parameters: the content of foaming agent andfoaming temperature.

Characteristics and Microstructure of a Hypereutectic Al-Si Alloy Powder by Ultrasonic Gas Atomization Process

A hypereutectic Al-Si alloy powder was prepared by ultrasonic gas atomization process. The morphologies, microstructure and phase constituent of the alloy powder were studied. The results showed that powder of the alloy was very fine and its microstructure was mainly consisted of Si crystals plus intermetallic compound A19FeSi3, which were.very fine and uniformly distributed.

Spheroidization of molybdenum powder by radio frequency thermal plasma

To control the morphology and particle size of dense spherical molybdenum powder prepared by radio frequency（RF） plasma from irregular molybdenum powder as a precursor, plasma process parameters were optimized in this paper. The effects of the carrier gas flow rate and molybdenum powder feeding rate on the shape and size of the final products were studied. The molybdenum powder morphology was examined using high-resolution scanning electron microscopy. The powder phases were analyzed by X-ray diffraction. The tap density and apparent density of the molybdenum powder were investigated using a Hall flow meter and a Scott volumeter. The optimal process parameters for the spherical molybdenum powder preparation are 50 g/min powder feeding rate and 0.6 m^3/h carrier gas rate. In addition, pure spherical molybdenum powder can be obtained from irregular powder, and the tap density is enhanced after plasma processing. The average size is reduced from 72 to 62 μm, and the tap density is increased from 2.7 to 6.2 g/cm^3. Therefore, RF plasma is a promising method for the preparation of high-density and high-purity spherical powders.

Transition of Y_2BaCuO_5 Phase in Powder Melting Processed YBa_2Cu_3O_(7-x) Superconductors

The morphology and the formation of Y2BaCuO5 phase in powder melting processed YBa2Cu3O7-x superconductors were investigated. The experimental results show the heat treatment can not change the shape of Y2BaCuO5 particles in powder melting processed samples. The formation of round Y2BaCuO5 phase is due to relative content of each constitution of precursor powders in powder melting process. For powder melting process, the excessive liquid phase is eliminated, which restrains the preferred growth of Y2BaCuO5 particles.

Preparation of Strontium Bismuth Tantalum (SBT) Fine Powder by Sol-Gel Process Using Bismuth Subnitrate as Bismuth Source

Strontium bismuth tantalum (SBT) fine power was prepared by Sol-Gel method. Pentaethoxy tantalum, strontium acetate and bismuth subnitrate were used as raw materials, and were dissolved in proper order in ethylene glycol to form transparent sol. The mixed precursor was dried at 80℃ and annealed at 800℃ for 1 h. Crystallized nanometer sized SBT fine powder was obtained and characterized by XRD.

On Numerical Modelling of Industrial Powder Compaction Processes for Large Deformation of Endochronic Plasticity at Finite Strains

Compaction processes are one the most important par ts of powder forming technology. The main applications are focused on pieces for a utomotive, aeronautic, electric and electronic industries. The main goals of the compaction processes are to obtain a compact with the geometrical requirements, without cracks, and with a uniform distribution of density. Design of such proc esses consist, essentially, in determine the sequence and relative displacements of die and punches in order to achieve such goals. A.B. Khoei presented a gener al framework for the finite element simulation of powder forming processes based on the following aspects; a large displacement formulation, centred on a total and updated Lagrangian formulation; an adaptive finite element strategy based on error estimates and automatic remeshing techniques; a cap model based on a hard ening rule in modelling of the highly non-linear behaviour of material; and the use of an efficient contact algorithm in the context of an interface element fo rmulation. In these references, the non-linear behaviour of powder was adequately desc ribed by the cap plasticity model. However, it suffers from a serious deficiency when the stress-point reaches a yield surface. In the flow theory of plasticit y, the transition from an elastic state to an elasto-plastic state appears more or less abruptly. For powder material it is very difficult to define the locati on of yield surface, because there is no distinct transition from elastic to ela stic-plastic behaviour. Results of experimental test on some hard met al powder show that the plastic effects were begun immediately upon loading. In such mater ials the domain of the yield surface would collapse to a point, so making the di rection of plastic increment indeterminate, because all directions are normal to a point. Thus, the classical plasticity theory cannot deal with such materials and an advanced constitutive theory is necessary. In the present paper, the constitutive equations of powder materials will be discussed via an endochronic theory of plasticity. This theory provides a unifi ed point of view to describe the elastic-plastic behaviour of material since it places no requirement for a yield surface and a ’loading function’ to disting uish between loading an unloading. Endochronic theory of plasticity has been app lied to a number of metallic materials, concrete and sand, but to the knowledge of authors, no numerical scheme of the model has been applied to powder material . In the present paper, a new approach is developed based on an endochronic rate independent, density-dependent plasticity model for describing the isothermal deformation behavior of metal powder at low homologous temperature. Although the concept of yield surface has not been explicitly assumed in endochronic theory, it is shown that the cone-cap plasticity yield surface (Fig.1), which is the m ost commonly used plasticity models for describing the behavior of powder materi al can be easily derived as a special case of the proposed endochronic theory. Fig.1 Trace of cone-cap yield function on the meridian pl ane for different relative density As large deformation is observed in powder compaction process, a hypoelastic-pl astic formulation is developed in the context of finite deformation plasticity. Constitutive equations are stated in unrotated frame of reference that greatly s implifies endochronic constitutive relation in finite plasticity. Constitutive e quations of the endochronic theory and their numerical integration are establish ed and procedures for determining material parameters of the model are demonstra ted. Finally, the numerical schemes are examined for efficiency in the model ling of a tip shaped component, as shown in Fig.2. Fig.2 A shaped tip component. a) Geometry, boundary conditio n and finite element mesh; b) density distribution at final stage of

The Design of a Graphical User Environment for Numerical Simulation of Powder Forming Processes

As computer simulation increasingly supports engine er ing design and manufacture, the requirement for a computer software environment providing an integration platform for computational engineering software increas es. A key component of an integrated environment is the use of computational eng ineering to assist and support solutions for complex design. Computer methods fo r structural, flow and thermal analysis are well developed and have been used in design for many years. Many software packages are now available which provi de an advanced capability. However, they are not designed for modelling of powde r forming processes. This paper describes the powder compaction software (PCS_SU T), which is designed for pre- and post-processing for computational simulatio n of the process compaction of powder. In the PCS_SUT software, the adaptive analysis of transient metal powder forming process is simulated by the finite element method based on deformation theories . The error estimates and adaptive remeshing schemes are applied for updated co -ordinate analysis. A generalized Newmark scheme is used for the time domain di scretization and the final nonlinear equations are solved by a Newton-Raphson p rocedure. An incremental elasto-plastic material model is used to simulate the compaction process. To describe the constitutive model of nonlinear behaviour of powder materials, a combination of Mohr-Coulomb and elliptical yield cap model is applied. This model reflects the yielding, frictional and densification char acteristics of powder along with strain and geometrical hardening which occurs d uring the compaction process. A hardening rule is used to define the dependence of the yield surface on the degree of plastic straining. A plasticity theory for friction is employed in the treatment of the powder-tooling interface. The inv olvement of two different materials, which have contact and relative movement in relation to each other, must be considered. A special formulation for friction modelling is coupled with a material formulation. The interface behaviour betwee n the die and the powder is modelled by using an interface element mesh. In the present paper, we have demonstrated pre- and post-processor finite elem ent software, written in Visual Basic, to generate the graphical model and visua lly display the computed results. The software consist of three main part: · Pre-processor: It is used to create the model, generate an app ropriate finite element grid, apply the appropriate boundary conditions, and vie w the total model. The geometric model can be used to associate the mesh with th e physical attributes such as element properties, material properties, or loads and boundary conditions. · Analysis: It can deal with two-dimensional and axi-symmetric applications for linear and non-linear behaviour of material in static and dyna mic analyses. Both triangular and quadrilateral elements are available in the e lement library, including 3-noded, 6-noded and 7-noded (T6B1) triangles and 4 -noded, 8-noded and 9-noded quadrilaterals. The direct implicit algorithm bas ed on the generalized Newmark scheme is used for the time integration and an aut omatic time step control facility is provided. For non-linear iteration, choice s among fully or modified Newton-Raphson method and quasi-Newton method, using the initial stiffness method, Davidon inverse method or BFGS inverse method, ar e possible. · Post-processor: It provides visualization of the computed resu lts, when the finite element model and analysis have been completed. Post-proce ssing is vital to allow the appropriate interpretation of the completed results of the finite element analysis. It provides the visual means to interpret the va st amounts of computed results generated. Finally, the powder behaviour during the compaction of a multi-level component is numerically simulated by the PCS_SUT software, as shown in Fig.1. The predict ive compaction forces at different displacements are computed and compared with the available experimental

Single-step Preparation of Nano-homogeneous NiO/YSZ Composite Anode for Solid Oxide Fuel Cells

Homogeneous co-precipitation and hydrothermal treatment were used to prepare nano- and highly dispersed Ni O/YSZ(yttria-stabilized zirconia) composite powders. Composite powders of size less than 100 nm were successfully prepared. This process did not require separate sintering of the YSZ and Ni O to be used as the raw materials for solid oxide fuel cells. The performance of a cell fabricated using the new powders(max.power density ~0.87 W/cm^2) was higher than that of a cell fabricated using conventional powders(max. power density ~0.73 W/cm^2). Co-precipitation and hydrothermal treatment proved to be very effective processes for reducing cell production costs as well as improving cell performance.

Strengthening and deformation mechanism of high-strength CrMnFeCoNi high entropy alloy prepared by powder metallurgy

Multiphase CrMnFeCoNi high-entropy alloys(HEAs)were prepared by a powder metallurgy process com-bining mechanical alloying(MA)and vacuum hot-pressing sintering(HPS).The single-phase face-centered cubic(FCC)HEA powder prepared by MA was sintered into a bulk HEA specimen containing FCC phase matrix along with precipitated M 23 C 6 phase and nanoscaleσphase particles.When the sintering temper-ature was 1223 K,the ultimate strength reaches 1300±11.6 MPa,and the elongation exceeds 4%±0.6%.Microstructural characterization reveals that the formation of nanoscale particles and deformation twins play critical roles in improving the strain hardening(SH)ability.Prolonging the MA time promoted the formation of the precipitated phase and enhanced the SH ability by increasing the number of precip-itated particles.The SH capacity increases significantly with increasing sintering temperature,which is attributed to a significant enhancement in the twinning capacity due to grain growth and the reduced number ofσphase particles.Through systematic studies,the planar glide of dislocations was found to be the main mode of deformation,while deformation twinning appeared as an auxiliary deformation mode when the twinning stress was reached.Although the formation of precipitates leads to grain bound-ary and precipitation strengthening effects,crack initiation is more prominent owing to increased grain boundary brittleness around the precipitated M 23 C 6 phase.The prominence of crack initiation is a contra-diction that must be reconciled with regard to precipitation strengthening.This work serves as a useful reference for the preparation of high-strength HEA parts by powder metallurgy.

In-situ fabrication of Al(Zn)-Al_2O_3 graded composite using the aluminothermic reaction during hot pressing

In INs study, the fabrication of multilayer AI（Zn）-A1203 with different volume fractions of A1203 was investigated. A1 and ZnO powders were milled by a plaaetaxy ball mill, after which five-layer functionally graded samples were produced flarough hot pressing at 580~C and 90 MPa pressure for 30 min. Formation of reinforcing A1203 particles occurred in the aluminum matrix via the aluminolkermic reaction. Determination of the ignition temperature of the aluminolkennic reaction was accomplished using differential lkermal and lkermo- gravimelric amlyses. Scaaming electron microscopy, energy dispersive spectroscopy, and X-ray diffractometery amlyses were utilized to characterize the specimens. The lkermal amlysis results showed that the ignition temperatures for the aluminolkennic reaction of layers with the highest and lowest ZnO contents were 667 and 670~C, respectively. Microslxuctural observation and chemical amlysis confirmed the fa- brication of AI（Zn）-A1203 functionally graded materials composites with precipitation of additional Zn in the matrix. Moreover, nearly dense functionally graded samples demonstrated minimum and maximum hacdness values of HV 75 and HV 130, respectively.

Physical Modeling of the Vacuum Circulation Refining Process of Molten Steel

The available studies in the literature on physical modeling of the vacuum circulation (RH, i.e. Ruhrstahl Heraeus) refining process of molten steel have briefly been reviewed. The latest advances made by the author with his research group have been summarized. Water modeling was employed to investigate the flow and mixing characteristics of molten steel under the RH and RH KTB (Kawasaki top blowing) conditions and the mass transfer features between molten steel and powder particles in the RH PTB (powder top blowing) refining. The geometric similarity ratio between the model and its prototype (a multifunction RH degasser of 90 t capacity) was 1:5. The effects of the related technological and structural factors were considered. These latest studies have revealed the flow and mixing characteristics of molten steel and the mass transfer features between molten steel and powder particles in these processes, and have provided a better understanding of the refining processes of molten steel.

Mathematical Modeling of the Vacuum Circulation Refining Process of Molten Steel

The available studies in the literature on mathematical modeling of the vacuum circulation (RH) refining process of molten steel have briefly been reviewed. The latest advances obtained by the author with his research group have been summarized. On the basis of the mass and momentum balances in the system, a new mathematical model for decarburization and degassing during the RH and RH KTB refining processes of molten steel was proposed and developed. The refining roles of the three reaction sites, i.e. the up snorkel zone, the droplet group and steel bath in the vacuum vessel, were considered in the model. It was assumed that the mass transfer of reactive components in the molten steel is the rate control step of the refining reactions. And the friction losses and drags of flows in the snorkels and vacuum vessel were all counted. The model was applied to the refining of molten steel in a multifunction RH degasser of 90 t capacity. The decarburization and degassing processes in the degasser under the RH and RH KTB operating conditions were modeled and analyzed using this model. Besides, proceeded from the two resistance mass transfer theory and the mass balance of sulphur in the system, a kinetic model for the desulphurization by powder injection and blowing in the RH refining of molten steel was developed. Modeling and predictions of the process of injecting and blowing the lime based powder flux under assumed operating modes with the different initial contents of sulphur and amounts of powder injected and blown in a RH degasser of 300 t capacity were carried out using the model. It was demonstrated that for the RH and RH KTB refining processes, and the desulphurization by powder injection and blowing in the RH refining, the results predicted by the models were all in good agreement respectively with data from industrial experiments and practice. These models may be expected to offer some useful information and a reliable basis for determining and optimizing the technologies of the RH and RH KTB refining and desulphurization by powder injection and blowing in the RH refining and for controlling the processes.

A Review of Glass and Crystallizations of Glass-Ceramics

The fundamental science behind glass and glass-ceramics in relation to research including syntheses, processing, characterization and applications are critically reviewed in this paper. The crystalline structure of the crystalline phases/s investigated in the literature is also discussed. Throughout this paper, the scene is set toward the overall picture of the rationale behind the choice of a glass system. Additionally, earlier reviews do not include the most recent literature in this fast-moving field. The main methods of synthesizing glasses and glass-ceramics are explained and described in relation to their applications. The paper concludes with recommendations for future research.

Highly thermal-conductive graphite flake/Cu composites prepared by sintering intermittently electroplated core-shell powders

Graphite flake/Cu composite has attracted tremendous attention as a promising heat sinks materials owing to its easy machinability and superior thermal properties. However, its preparation process still faces several technological limitations including complex, time-consuming and costly synthetic approaches. In this work, a facile and scalable intermittently electroplated method is applied to prepare Cu-coated graphite flake composite powders, which are subsequently sintered into dense composite bulks. The results show that the graphite flake is successfully coated with a uniform and compact Cu shell,which effectively inhibits the segregation accumulation of graphite flakes and contributes to homogeneous distribution of graphite in the sintered graphite flake/Cu composites. The as-sintered composites exhibit an excellent thermal conductivity of 710 W·m-1·K-1and an outstanding bending strength of 93 MPa. Such performance, together with the simple, efficient powder-preparation process, suggests that the present strategy may open up opportunities for the development of thermal management materials.

Recent progress in porous Mg-based foam preparation approaches:effect of processing parameters on structure and mechanical property

Porous metals are a class of cellular materials with lightweight and unique mechanical,electrical,thermal,physical and acoustic characteristics.Magnesium and magnesium alloy foams have exhibited excellent advantages.In particular,open-cell Mg-based foams(porous Mg/Mg alloy foams)have been used for bioresorbable implants,CO_(2)trapping systems,filters,heat exchangers,absorbent panels and many other applications.While significant progress has been taken in producing porous Mg-based foams with good structure-property relations,but with a large number of different processing parameters,different mechanical properties and pore morphologies of each porous Mg-based foam,it is essential to understand the individual effects of each aspect of the parameters.Therefore,the present article summarized the effects of available processing parameters on the structure and mechanical properties of the porous Mg-based foams.Finally,the future perspectives to enhance the structure and properties of porous Mg/Mg alloy foams were discussed.

A hydrometallurgical method of energy saving type for separation of rare earth elements from rare earth polishing powder wastes with middle fraction of ceria

This study described a hydrometallurgical method to investigate the separation of rare earth elements（REEs）from rare earth polishing powder wastes（REPPWs）containing large amounts of rare earth oxides with a major phase of CeO2 and minor phases of La2O3,Pr2O3,and Nd2O3 using a process devised by the authors.The suggested approach consisted of five processes：the synthesis of NaR E（SO4）2·xH2O from rare earth oxides in Na2SO4-H2SO4-H2 O solutions（Process 1）,the conversion of NaR E（SO4）2·xH2O into RE（OH）3 using NaO H（Process 2）,and the oxidation of Ce（OH）3 into Ce（OH）4 using air with O2 injection（Process 3）,followed by Processes 4 and 5 for separation of REEs by acid leaching using HCl and H2SO4,respectively.To confirm the high yield of NaR E（SO4）2·xH2O in Process 1,experiments were carried out under various Na2SO4 concentrations（0.4–2.5 mol/L）,sulfuric acid concentrations（6–14 mol/L）,and reaction temperatures（95–125 oC）.In addition,the effect of the pH value on the separation of Ce（OH）4 in HCl-H2 O solutions with Ce（OH）4,La-,Pr-,and Nd（OH）3 in Process 4 was also investigated.On the basis of above results,the possibility of effective separation of REEs from REPPWs could be confirmed.

Highly ductile hypereutectic Al-Si alloys fabricated by selective laser melting

In the endeavor to maximize the refinement effect of primary Si and alleviate the inherent brittleness of hypereutectic Al-Si alloy,the approach of coating P as a modifier on powder was adopted.The ultimate aim was to create more heterogeneous fine Al P nucleus and enhance the nucleation efficiency of primary Si on Al P to refine the coarse primary Si to nano-scale during 3D printing.In the combination of large undercooling and high density of nucleation sites,the size of primary Si was successfully refined to 200–300 nm and the divorced eutectic was also induced to modify the microstructure of matrix.In the presence of nano-scale primary Si,the melting pool boundary(MPB)feature disappeared and the fracture mechanism also changed from load transfer to interfacial fracture.Compared with the pristine alloy,the ductility was increased four times without significantly changing the ultimate tensile strength(UTS)and wear resistance.The improvement of ductility is attributed to the refinement of primary Si,the disappearance of MPB features and the formation of divorced eutectic.The optimal tensile properties were:UTS-482 MPa,yield strength-320 MPa and ductility of 8.1%at 0.05 wt.%P.These are comparable to those for high-strength Al alloys.