C. Suryanarayana

The science and technology of mechanical alloying

Abstract Mechanical alloying (MA) is a powder metallurgy processing technique involving cold welding, fracturing, and rewelding of powder particles in a high-energy ball mill, and has now become an established commercial technique to produce oxide dispersion strengthened (ODS) nickel- and iron-based materials. MA is also capable of synthesizing a variety of metastable phases, and in this respect, the capabilities of MA are similar to those of another important non-equilibrium processing technique, viz., rapid solidification processing (RSP). However, the “science” of MA is being investigated only during the past 10 years or so. The technique of mechanochemistry, on the other hand, has had a long history and the materials produced in this way have found a number of technological applications, e.g., in areas such as hydrogen storage materials, heaters, gas absorbers, fertilizers, catalysts, cosmetics, and waste management. The present paper discusses the basic mechanisms of formation of metastable phases (specifically supersaturated solid solutions and amorphous phases) by the technique of MA and these aspects are compared with those of RSP. Additionally, the variety of technological applications of mechanically alloyed products are highlighted.

Synthesis, properties and applications of titanium aluminides

Attractive elevated-temperature properties and low density make the titanium aluminides very interesting for both engine and airframe applications, particularly in the aerospace industry. The challenge to the materials scientist is to maintain these characteristics while building-in “forgiveness”. The basic phase diagram and crystal structure of both the Ti3Al and TiAl phases are reviewed, followed by a consideration of chemistry-processing-microstructure-deformation/fracture-mechanical property relationships in monolithic material. Conventional and innovative synthesis methods are presented, including use of hydrogen as a temporary alloying element. Composite concepts as a method to enhance not only “forgiveness” but also elevated-temperature behaviour are discussed. Environmental effects are evaluated prior to consideration of present and projected applications of both monolithic and composite material. It is concluded that while the titanium aluminides in monolithic form can be used now in non-demanding applications, much further research and development is required before this material class can be used in critical applications, especially in composite concepts.

Nanocrystalline materials - Current research and future directions

Nanocrystalline materials, with a grain size of typically <100 nm, are a new class of materials with properties vastly different from and often superior to those of the conventional coarse-grained materials. These materials can be synthesized by a number of different techniques and the grain size, morphology, and composition can be controlled by controlling the process parameters. In comparison to the coarse-grained materials, nanocrystalline materials show higher strength and hardness, enhanced diffusivity, and superior soft and hard magnetic properties. Limited quantities of these materials are presently produced and marketed in the US, Canada, and elsewhere. Applications for these materials are being actively explored. The present article discusses the synthesis, structure, thermal stability, properties, and potential applications of nanocrystalline materials.

Iron-based bulk metallic glasses

Abstract The current status of research and development in Fe-based bulk metallic glasses (BMGs) is reviewed. Bulk metallic glasses are relatively new materials possessing a glassy structure and large section thickness. These materials have an exciting combination of properties such as high mechanical strength, good thermal stability, large supercooled liquid region and potential for easy forming. Ever since the first synthesis of an Fe-based BMG in an Fe–Al–Ga–P–C–B system in 1995, there has been intense activity on the synthesis and characterisation of Fe-based BMGs. These BMGs exhibit some unique characteristics which have not been obtained in conventional Fe-based crystalline alloys. This uniqueness has led to practical uses of these bulk glassy alloys as soft magnetic and structural materials. This review presents the recent results on the glass-forming ability, structure, thermal stability, mechanical properties, corrosion behaviour, soft magnetic properties and applications of Fe-based bulk glassy alloys developed during the last 15 years. This review also highlights the advanced analysis of their properties which has contributed significantly to the progress in understanding and developing of the Fe-based BMGs. The future prospects of Fe-based BMGs have also been presented.

Structure and properties of nanocrystalline materials

The present article reviews the current status of research and development on the structure and properties of nanocrystalline materials. Nanocrystalline materials are polycrystalline materials with grain sizes of up to about 100 nm. Because of the extremely small dimensions, a large fraction of the atoms in these materials is located at the grain boundaries, and this confers special attributes. Nanocrystalline materials can be prepared by inert gas-condensation, mechanical alloying, plasma deposition, spray conversion processing, and many other methods. These have been briefly reviewed.A clear picture of the structure of nanocrystalline materials is emerging only now. Whereas the earlier studies reasoned out that the structure of grain boundaries in nanocrystalline materials was quite different from that in coarse-grained materials, recent studies using spectroscopy, high-resolution electron microscopy, and computer simulation techniques showed unambiguously that the structure of the grain boundaries is the same in both nanocrystalline and coarse-grained materials. A critical analysis of this aspect and grain growth is presented.The properties of nanocrystalline materials are very often superior to those of conventional polycrystalline coarse-grained materials. Nanocrystalline materials exhibit increased strength/hardness, enhanced diffusivity, improved ductility/toughness, reduced density, reduced elastic modulus, higher electrical resistivity, increased specific heat, higher thermal expansion coefficient, lower thermal conductivity, and superior soft magnetic properties in comparison to conventional coarse-grained materials. Recent results on these properties, with special emphasis on mechanical properties, have been discussed.New concepts of nanocomposites and nanoglasses are also being investigated with special emphasis on ceramic composites to increase their strength and toughness. Even though no components made of nanocrystalline materials are in use in any application now, there appears to be a great potential for applications in the near future. The extensive investigations in recent years on structure-property correlations in nanocrystalline materials have begun to unravel the complexities of these materials, and paved the way for successful exploitation of the alloy design principles to synthesize better materials than hitherto available.

Grain size effects in nanocrystalline materials

Nanocrystalline materials have a grain size of only a few nanometers and are expected to possess very high hardness and strength values. Even though the hardness/strength is expected to increase with a decrease in grain size, recent observations have indicated that the hardness increases in some cases and decreases in other cases. A careful analysis of the available results on the basis of existing models suggests that there is a critical grain size below which the triple junction volume fraction increases considerably over the grain boundary volume fraction and this is suggested to be responsible for the observed softening at small grain sizes.

Review: a decade of quenching from the melt

The technique of rapidly quenching metals and alloys from the melt developed in 1960 by Duwez and his collaborators has gained wide popularity. The extremely high cooling rates (106 to 108° C/sec) attainable with these techniques have yielded supersaturated solid solutions, non-equilibrium crystalline phases and also amorphous alloys. The fascinating results obtained so far, particularly the unusual structures and properties of the new products, are extensively reviewed in this article.

Effect of clustering on the mechanical properties of SiC particulate- reinforced aluminum alloy 2024 metal matrix composites

Abstract Al 2024–SiC metal matrix composite (MMC) powders produced by centrifugal atomization were hot extruded to investigate the effect of clustering on their mechanical properties. Fracture toughness and tension tests were conducted on specimens reinforced with different volume fractions of SiC. A model was proposed to suggest that the strength of the MMCs could be estimated from the load transfer model approach that takes into consideration the extent of clustering. This model has been successful in predicting the experimentally observed strength and fracture toughness values of the Al 2024–SiC MMCs. On the basis of experimental observations, it is suggested that the strength of particulate-reinforced MMCs may be calculated from the relation: σ y = σ m V m + σ r ( V r − V c )− σ r V c , where σ and V represent the yield strength and volume fraction, respectively, and the subscripts m, r, and c represent the matrix, reinforcement, and clusters, respectively.

Rapid quenching from the melt: An annotated bibliography 1958–72

A comprehensive classified list of annotated references on rapid cooling from the liquid to the solid state is presented, covering the period 1958 to 1971 and embracing the range of cooling rates greater than ∼105 K sec−1. An index of authors and of alloys studied is appended, supplemented with a list of references for 1972, as known at time of going to press.

Nanocrystalline titanium-magnesium alloys through mechanical alloying

The solid solubility of magnesium in titanium under equilibrium conditions is reported to be extremely small. Mechanical alloying of a mixture of titanium and magnesium powders resulted in the formation of nanocrystalline (10–15 nm in size) grains of Ti–Mg solid solution. This solid solution has a metastable fcc structure with a = 0.426 nm and contains about 3 wt.% (6 at.%) magnesium in it. It is suggested that the fcc structure has formed as a result of the heavy mechanical deformation of the hep structure introduced during milling. High temperature annealing of the metastable solid solution led to its decomposition forming the equilibrium phases, viz., elemental titanium and magnesium.