Claire E. J. Dancer

A trapped field of >3 T in bulk MgB2 fabricated by uniaxial hot pressing

A trapped field of over 3 T has been measured at 17.5 K in a magnetized stack of two disc-shaped bulk MgB2 superconductors of diameter 25 mm and thickness 5.4 mm. The bulk MgB2 samples were fabricated by uniaxial hot pressing, which is a readily scalable, industrial technique, to 91% of their maximum theoretical density. The macroscopic critical current density derived from the trapped field data using the Biot–Savart law is consistent with the measured local critical current density. From this we conclude that critical current density, and therefore trapped field performance, is limited by the flux pinning available in MgB2, rather than by lack of connectivity. This suggests strongly that both increasing sample size and enhancing pinning through doping will allow further increases in trapped field performance of bulk MgB2.

Microwave dielectric characterisation of 3D-printed BaTiO3/ABS polymer composites

3D printing is used extensively in product prototyping and continues to emerge as a viable option for the direct manufacture of final parts. It is known that dielectric materials with relatively high real permittivity—which are required in important technology sectors such as electronics and communications—may be 3D printed using a variety of techniques. Among these, the fused deposition of polymer composites is particularly straightforward but the range of dielectric permittivities available through commercial feedstock materials is limited. Here we report on the fabrication of a series of composites composed of various loadings of BaTiO3 microparticles in the polymer acrylonitrile butadiene styrene (ABS), which may be used with a commercial desktop 3D printer to produce printed parts containing user-defined regions with high permittivity. The microwave dielectric properties of printed parts with BaTiO3 loadings up to 70 wt% were characterised using a 15 GHz split post dielectric resonator and had real relative permittivities in the range 2.6–8.7 and loss tangents in the range 0.005–0.027. Permittivities were reproducible over the entire process, and matched those of bulk unprinted materials, to within ~1%, suggesting that the technique may be employed as a viable manufacturing process for dielectric composites.

Fabrication and properties of dense ex situ magnesium diboride bulk material synthesized using spark plasma sintering

High density ex situ magnesium diboride bulks were synthesized from commercial MgB2 powder using spark plasma sintering under a range of applied uniaxial pressures between 16 and 80 MPa. The microstructure was characterized using x-ray diffraction, scanning electron microscopy, polarized optical microscopy, Vickers hardness measurements, and density measurements using the Archimedes method. By combining these data with those for other bulk samples we have developed a correlation curve for the hardness and density for magnesium diboride for relative densities of 60–100%. The superconducting properties were determined using magnetization measurements. Comparison to samples of significantly higher porosity indicates a positive correlation between magnetization critical current density and bulk density for magnesium diboride bulks up to around 90% density. Above this level other microstructural processes such as grain growth begin to influence the critical current density, suggesting that full elimination of porosity is not necessary to obtain high critical current density. We conclude that the best superconducting properties are likely to be obtained with a combination of small grain size and minimal porosity.

Manufacture of electrical and magnetic graded and anisotropic materials for novel manipulations of microwaves.

Spatial transformations (ST) provide a design framework to generate a required spatial distribution of electrical and magnetic properties of materials to effect manipulations of electromagnetic waves. To obtain the electromagnetic properties required by these designs, the most common materials approach has involved periodic arrays of metal-containing subwavelength elements. While aspects of ST theory have been confirmed using these structures, they are often disadvantaged by narrowband operation, high losses and difficulties in implementation. An all-dielectric approach involves weaker interactions with applied fields, but may offer more flexibility for practical implementation. This paper investigates manufacturing approaches to produce composite materials that may be conveniently arranged spatially, according to ST-based designs. A key aim is to highlight the limitations and possibilities of various manufacturing approaches, to constrain designs to those that may be achievable. The article focuses on polymer-based nano- and microcomposites in which interactions with microwaves are achieved by loading the polymers with high-permittivity and high-permeability particles, and manufacturing approaches based on spray deposition, extrusion, casting and additive manufacture.

Flash sintering of ceramic materials

During flash sintering, ceramic materials can sinter to high density in a matter of seconds while subjected to electric field and elevated temperature. This process, which occurs at lower furnace temperatures and in shorter times than both conventional ceramic sintering and field-assisted methods such as spark plasma sintering, has the potential to radically reduce the power consumption required for the densification of ceramic materials. This paper reviews the experimental work on flash sintering methods carried out to date, and compares the properties of the materials obtained to those produced by conventional sintering. The flash sintering process is described for oxides of zirconium, yttrium, aluminium, tin, zinc, and titanium; silicon and boron carbide, zirconium diboride, materials for solid oxide fuel applications, ferroelectric materials, and composite materials. While experimental observations have been made on a wide range of materials, understanding of the underlying mechanisms responsible for the onset and latter stages of flash sintering is still elusive. Elements of the proposed theories to explain the observed behaviour include extensive Joule heating throughout the material causing thermal runaway, arrested by the current limitation in the power supply, and the formation of defect avalanches which rapidly and dramatically increase the sample conductivity. Undoubtedly, the flash sintering process is affected by the electric field strength, furnace temperature and current density limit, but also by microstructural features such as the presence of second phase particles or dopants and the particle size in the starting material. While further experimental work and modelling is still required to attain a full understanding capable of predicting the success of the flash sintering process in different materials, the technique non-etheless holds great potential for exceptional control of the ceramic sintering process.

Heavily loaded ferrite-polymer composites to produce high refractive index materials at centimetre wavelengths

A cold-pressing technique has been developed for fabricating composites composed of a polytetrafluoroethylene-polymer matrix and a wide range of volume-fractions of MnZn-ferrite filler (0%–80%). The electromagnetic properties at centimetre wavelengths of all prepared composites exhibited good reproducibility, with the most heavily loaded composites possessing simultaneously high permittivity (180 ± 10) and permeability (23 ± 2). The natural logarithm of both the relative complex permittivity and permeability shows an approximately linear dependence with the volume fraction of ferrite. Thus, this simple method allows for the manufacture of bespoke materials required in the design and construction of devices based on the principles of transformation optics.

The effects of attrition and ball milling on the properties of magnesium diboride

Commercially produced magnesium diboride powder was modified by attrition milling and ball milling in propan-2-ol for various durations. These powders were characterized by means of particle size distribution measurements using laser diffraction, impurity analysis using x-ray diffraction, energy dispersive spectroscopy and x-ray photoelectron spectroscopy, and scanning electron microscopy, and were then used to produce magnesium diboride samples through pressureless heat treatment at peak temperatures up to 1100 °C. X-ray diffraction, scanning electron microscopy, Vickers hardness measurements, and density measurements using the Archimedes method were used to characterize the properties of the samples, and a determination of their superconducting properties using the magnetization method was carried out. Magnesium diboride produced from powder milled under certain conditions had a higher Jc, mag than samples produced from as-purchased powder, but the relationship between the milling duration or energy and the superconducting performance is a complex one, affected by both the particle size and the impurity content of the starting powder.