Nouari Saheb

Spark plasma sintering of metals and metal matrix nanocomposites: a review

Metal matrix nanocomposites (MMNCs) are thosemetal matrix composites where the reinforcement is of nanometer dimensions, typically less than 100nm in size. Also, it is possible to have both the matrix and reinforcement phases of nanometer dimensions. The improvement in mechanical properties of MMNCs is attributed to the size and strength of the reinforcement as well as to the fine grain size of the matrix. Spark plasma sintering has been used extensively over the past years to consolidate wide range of materials including nanocomposites and was shown to be effective noneconventional sintering method for obtaining fully dense materials with preserved nanostructure features. The objective of this work is to briefly present the spark plasma sintering process and review published work on spark-plasma-sintered metals and metal matrix nanocomposites.

Spark plasma and microwave sintering of Al6061 and Al2124 alloys

Despite the importance of aluminum alloys as candidate materials for applications in aerospace and automotive industries, very little work has been published on spark plasma and microwave processing of aluminum alloys. In the present work, the possibility was explored to process Al2124 and Al6061 alloys by spark plasma and microwave sintering techniques, and the microstructures and properties were compared. The alloys were sintered for 20 min at 400, 450, and 500°C. It is found that compared to microwave sintering, spark plasma sintering is an effective way to obtain homogenous, dense, and hard alloys. Fully dense (100%) Al6061 and Al2124 alloys were obtained by spark plasma sintering for 20 min at 450 and 500°C, respectively. Maximum relative densities were achieved for Al6061 (92.52%) and Al2124 (93.52%) alloys by microwave sintering at 500°C for 20 min. The Vickers microhardness of spark plasma sintered samples increases with the increase of sintering temperature from 400 to 500°C, and reaches the values of Hv 70.16 and Hv 117.10 for Al6061 and Al2124 alloys, respectively. For microwave sintered samples, the microhardness increases with the increase of sintering temperature from 400 to 450°C, and then decreases with the further increase of sintering temperature to 500°C.

Characterization of Nanoreinforcement Dispersion in Inorganic Nanocomposites: A Review

Metal and ceramic matrix composites have been developed to enhance the stiffness and strength of metals and alloys, and improve the toughness of monolithic ceramics, respectively. It is possible to further improve their properties by using nanoreinforcement, which led to the development of metal and ceramic matrix nanocomposites, in which case, the dimension of the reinforcement is on the order of nanometer, typically less than 100 nm. However, in many cases, the properties measured experimentally remain far from those estimated theoretically. This is mainly due to the fact that the properties of nanocomposites depend not only on the properties of the individual constituents, i.e., the matrix and reinforcement as well as the interface between them, but also on the extent of nanoreinforcement dispersion. Therefore, obtaining a uniform dispersion of the nanoreinforcement in the matrix remains a key issue in the development of nanocomposites with the desired properties. The issue of nanoreinforcement dispersion was not fully addressed in review papers dedicated to processing, characterization, and properties of inorganic nanocomposites. In addition, characterization of nanoparticles dispersion, reported in literature, remains largely qualitative. The objective of this review is to provide a comprehensive description of characterization techniques used to evaluate the extent of nanoreinforcement dispersion in inorganic nanocomposites and critically review published work. Moreover, methodologies and techniques used to characterize reinforcement dispersion in conventional composites, which may be used for quantitative characterization of nanoreinforcement dispersion in nanocomposites, is also presented.

Matrix Structure Evolution and Nanoreinforcement Distribution in Mechanically Milled and Spark Plasma Sintered Al-SiC Nanocomposites

Development of homogenous metal matrix nanocomposites with uniform distribution of nanoreinforcement, preserved matrix nanostructure features, and improved properties, was possible by means of innovative processing techniques. In this work, Al-SiC nanocomposites were synthesized by mechanical milling and consolidated through spark plasma sintering. Field Emission Scanning Electron Microscope (FE-SEM) with Energy Dispersive X-ray Spectroscopy (EDS) facility was used for the characterization of the extent of SiC particles’ distribution in the mechanically milled powders and spark plasma sintered samples. The change of the matrix crystallite size and lattice strain during milling and sintering was followed through X-ray diffraction (XRD). The density and hardness of the developed materials were evaluated as function of SiC content at fixed sintering conditions using a densimeter and a digital microhardness tester, respectively. It was found that milling for 24 h led to uniform distribution of SiC nanoreinforcement, reduced particle size and crystallite size of the aluminum matrix, and increased lattice strain. The presence and amount of SiC reinforcement enhanced the milling effect. The uniform distribution of SiC achieved by mechanical milling was maintained in sintered samples. Sintering led to the increase in the crystallite size of the aluminum matrix; however, it remained less than 100 nm in the composite containing 10 wt.% SiC. Density and hardness of sintered nanocomposites were reported and compared with those published in the literature.

The synthesis of nanostructured WC-based hardmetals using mechanical alloying and their direct consolidation

Tungsten carbide- (WC-) based hardmetals or cemented carbides represent an important class of materials used in a wide range of industrial applications which primarily include cutting/drilling tools and wear resistant components. The introduction and processing of nanostructured WC-based cemented carbides and their subsequent consolidation to produce dense components have been the subject of several investigations. One of the attractive means of producing this class of materials is bymechanical alloying technique. However, one of the challenging issues in obtaining the right end-product is the possible loss of the nanocrystallite sizes due to the undesirable grain growth during powder sintering step. Many research groups have engaged in multiple projects aiming at exploring the right path of consolidating the nanostructured WC-based powders without substantially loosing the attained nanostructure. The present paper highlights some key issues related to powder synthesis and sintering of WCbased nanostructured materials using mechanical alloying. The path of directly consolidating the powders using nonconventional consolidation techniques will be addressed and some light will be shed on the advantageous use of such techniques. Cobaltbonded hardmetals will be principally covered in this work along with an additional exposure of the use of other binders in the WCbased hardmetals.

Phase transformation and sintering behaviour of mullite and mullite–zirconia composite materials

Abstract Abstract Mullite is one of the most promising engineering materials for applications at elevated temperatures, but has poor mechanical properties at ambient temperature; therefore, it is usually reinforced with particles, fibres or whiskers to improve its properties. Among particles added to mullite are ZrO2 particles which improve its fracture toughness through the well known process of phase transformation from tetragonal to monoclinic in zirconia particles. The aim of the present work is to explore the utilisation of Algerian kaolin, α-Al2O3 and ZrO2 to synthesise mullite–ZrO2 composites through reaction sintering and investigate phase transformation and sintering behaviour of the composites. The raw materials were mixed through planetary ball milling followed by attrition milling. Compacted samples were sintered at temperatures between 1100 and 1600°C for 2 h. The bulk density was measured by the water immersion method. X-ray diffraction (Rietveld method) was used to characterise phases present in the sintered samples. It was found that the zirconia phase retained its tetragonal structure with the addition of up to 16% zirconia. The formation of primary mullite in all samples was complete at 1250°C. The cristobalite started to form at 1150°C, and disappeared at 1300°C in the samples of mullite, and at 1250°C when ZrO2 was added. The zircon compound ZrSiO4 started to form at 1250°C and completely disappeared at 1400°C. The increase in ZrO2 ratio promoted the formation of grains with spherical shape.

Differential thermal analysis of mullite formation from Algerian kaolin

Abstract In the present work, the kinetics of mullite (3Al2O3.2SiO2) formation from Algerian kaolin was investigated using differential thermal analysis (DTA). The raw kaolin was wet ball milled for 5 h followed by attrition milling for 1 h. Differential thermal and thermogravimetric (DTA/TG) experiments were carried out on samples between room temperature and 1350°C at heating rates of 5, 10, 20 and 40°C min−1. The temperature of mullite crystallisation was found to be ∼1005°C. The activation energies measured from isothermal and non-isothermal treatments were around 1290 and 1260 kJ mol−1 respectively. The growth morphology parameters n (Avrami parameter which indicates the crystallisation mode) and m (a numerical factor which depends on the dimensionality of crystal growth) were found to be almost equal to 1˙5. Analysis of the results showed that bulk nucleation was dominant in mullite crystallisation followed by three-dimensional growth of mullite crystals with polyhedron-like morphology controlled by diffusion from a constant number of nuclei.

Effect of MgO addition and sintering parameters on mullite formation through reaction sintering kaolin and alumina

Abstract In the present work, the influence of MgO addition and sintering parameters on the formation and densification of mullite was investigated. The morphology of powders and the microstructure of the sintered samples were characterised by means of a scanning electron microscope. X-ray diffraction was used to characterise phases formed in sintered samples. The density of sintered samples was measured using a densimeter and quantified according to the Archimedes principle. MgO was added at 1, 2, 3, 4, 5 and 6 wt-% to kaolin and alumina and the powders were ball milled for 5 h then uniaxially compacted at 75 MPa and finally sintered at 1500, 1550, 1600 and 1650°C for 2, 4, 6 and 8 h. It was found that addition of MgO not only affected mullite formation but also promoted grain growth. For samples containing 0, 1 and 2 wt-%MgO only mullite was formed. While, in addition to mullite, Al2O3 was present in sample containing 3 wt-%MgO. At higher MgO content (4, 5 and 6 wt-%), three phases, i.e. mullite, Al2O3 and spinel, were formed. Addition of 1 wt-%MgO increased the density of all samples for all sintering times and higher densities corresponded to higher sintering temperatures. At higher MgO content, higher temperatures led to lower densities and lower temperatures led to higher densities for almost all sintering times.

Towards sensor array materials: can failure be delayed?

Abstract Further to prior development in enhancing structural health using smart materials, an innovative class of materials characterized by the ability to feel senses like humans, i.e. ‘nervous materials’, is discussed. Designed at all scales, these materials will enhance personnel and public safety, and secure greater reliability of products. Materials may fail suddenly, but any system wishes that failure is known in good time and delayed until safe conditions are reached. Nervous materials are expected to be the solution to this statement. This new class of materials is based on the novel concept of materials capable of feeling multiple structural and external stimuli, e.g. stress, force, pressure and temperature, while feeding information back to a controller for appropriate real-time action. The strain–stress state is developed in real time with the identified and characterized source of stimulus, with optimized time response to retrieve initial specified conditions, e.g. shape and strength. Sensors are volumetrically embedded and distributed, emulating the human nervous system. Immediate applications are in aircraft, cars, nuclear energy and robotics. Such materials will reduce maintenance costs, detect initial failures and delay them with self-healing. This article reviews the common aspects and challenges surrounding this new class of materials with types of sensors to be embedded seamlessly or inherently, including appropriate embedding manufacturing techniques with modeling and simulation methods.

Fiber-Embedded Metallic Materials: From Sensing towards Nervous Behavior

Embedding of fibers in materials has attracted serious attention from researchers and has become a new research trend. Such material structures are usually termed “smart” or more recently “nervous”. Materials can have the capability of sensing and responding to the surrounding environmental stimulus, in the former, and the capability of feeling multiple structural and external stimuli, while feeding information back to a controller for appropriate real-time action, in the latter. In this paper, embeddable fibers, embedding processes, and behavior of fiber-embedded metallic materials are reviewed. Particular emphasis has been given to embedding fiber Bragg grating (FBG) array sensors and piezo wires, because of their high potential to be used in nervous materials for structural health monitoring. Ultrasonic consolidation and laser-based layered manufacturing processes are discussed in detail because of their high potential to integrate fibers without disruption. In addition, current challenges associated with embedding fibers in metallic materials are highlighted and recommendations for future research work are set.