Xiaochun Li

Processing and properties of magnesium containing a dense uniform dispersion of nanoparticles

Magnesium is a light metal, with a density two-thirds that of aluminium, is abundant on Earth and is biocompatible; it thus has the potential to improve energy efficiency and system performance in aerospace, automobile, defence, mobile electronics and biomedical applications. However, conventional synthesis and processing methods (alloying and thermomechanical processing) have reached certain limits in further improving the properties of magnesium and other metals. Ceramic particles have been introduced into metal matrices to improve the strength of the metals, but unfortunately, ceramic microparticles severely degrade the plasticity and machinability of metals, and nanoparticles, although they have the potential to improve strength while maintaining or even improving the plasticity of metals, are difficult to disperse uniformly in metal matrices. Here we show that a dense uniform dispersion of silicon carbide nanoparticles (14 per cent by volume) in magnesium can be achieved through a nanoparticle self-stabilization mechanism in molten metal. An enhancement of strength, stiffness, plasticity and high-temperature stability is simultaneously achieved, delivering a higher specific yield strength and higher specific modulus than almost all structural metals.

Thermal behavior of a metal embedded fiber Bragg grating sensor

With embedded sensors it is possible to monitor structural parameters at critical locations which are not accessible to ordinary sensors. Recently, the fiber optic sensor has emerged as a promising technology to be integrated with structures. The embedding of fiber optic sensors into composites and some metals, especially those with low melting points, have been reported. However, all reported embedding techniques so far are either complicated or it is difficult to achieve coherent bonding with low residue stresses. Thus, it is of interest to pursue some economical ways to embed fiber optic sensors into metallic structures with low residue stresses. In this work, a new technique is proposed for embedding a fiber optic sensor into metallic structures, such as nickel, with minimized residue stress. Fiber Bragg grating (FBG) sensors have been embedded into nickel structures. The thermal performance of such an embedded FBG sensor is studied. Higher temperature sensitivity is demonstrated for the embedded FBG sensors. For temperature measurements, the embedded FBG sensor yields an accuracy of about 2 °C. Under rapid temperature changes, it is found that thermal stresses due to the temperature gradient in the metallic structures would be the main cause for errors.

Ultrasonic Cavitation Based Nanomanufacturing of Bulk Aluminum Matrix Nanocomposites

Lightweight metal–matrix nanocomposites (MMNCs) (metal matrix with nanosized ceramic particles) can be of significance for automobile, aerospace, and numerous other applications. It would be advantageous to develop effective nanomanufacturing methods for fabrication of bulk components of aluminum based MMNCs through solidification processing. However, it is extremely difficult to disperse nanosized ceramic particles uniformly in molten aluminum. In this paper, a high power ultrasonic probe is used to disperse nanosized SiC particles into molten aluminum alloy A356. Experimental results show that the ultrasonic cavitation based dispersion of nanoparticles in molten aluminum alloy is effective. The uniform nanoparticle dispersion in the Al alloy matrix resulted in significantly improved mechanical properties. To enhance the nanomanufacturing efficiency, various nanoparticle feeding techniques were explored and experimental results are presented.

Semi-solid forming of metal-matrix nanocomposites

Semi-solid casting (SSC) techniques have proven useful in the mass production of high integrity castings for the automotive and other industries. Recent research has shown metal matrix nanocomposite (MMNC) materials to have greatly improved properties in comparison to their base metals. However, current methods of MMNC production are costly and time consuming. Thus development of a process that combines the integrity and cost effectiveness of semi-solid casting with the property improvement of MMNCs would have the potential to greatly improve cast part quality available to engineers in a wide variety of industries. This paper presents a method of combining SSC with MMNC in a way that benefits from MMNCs’ tendency to naturally form the globular microstructure necessary for SSC. This method uses ultrasonically dispersed nanoparticles as nucleating agents to achieve globular primary grains such that fluidity is maintained even at high solid fractions. Once particle dispersion is achieved, the material needs no further processing to become a semi-solid slurry of globular primary grains as it cools. This quiescent method of slurry production, while still imposing some constraints on cooling rates, has a large process window making this process capable of industrial rates of throughput. It was found that the key factor to achieving globular microstructure is a sufficiently slow cooling rate at the onset of solidification such that particle-induced nucleation can occur. Once nucleation occurs, continued cooling is virtually unconstrained, with globular microstructure evident in quenched samples as well as samples cooled at rates as slow as 1 °C/min. This method was demonstrated in several material systems using zinc (Zn), aluminum (Al), and magnesium (Mg) alloys and nanoparticles of aluminum oxide (Al2O3), silicon carbide (SiC), and titanium oxide (TiO2). Additionally, several nucleation models are examined for applicability to nanoscale composites.

Theoretical study and pathways for nanoparticle capture during solidification of metal melt

Nanocomposites can provide exciting physical, chemical, and mechanical properties for numerous applications. The solidification processing method has great potential for economical fabrication of bulk nanocomposites, especially for those with crystalline materials as the matrix, such as metal matrix nanocomposites (MMNCs). However, it is extremely difficult to effectively capture nanoparticles (less than 100 nm) into the solidification fronts during solidification. It is thus very important to initiate a theoretical study to examine the physics that governs the interactions between nanoparticles and the solidification front, and to provide enabling pathways for effective nanoparticle capture during solidification. The aim of this paper is to establish a theoretical framework for the fundamental understanding of nanoparticle capture during solidification of metal melt in order to obtain bulk MMNCs. A thermodynamically favorable condition is set as the starting point for further theoretical analysis of the three-party model system, namely a nanoparticle-metal-melt-solidification front. Three key interaction potentials, the interfacial energy at short range (0.2-0.4 nm), the van der Waals potential (especially at a longer range beyond 0.4 nm and up to ∼10 nm) and the Brownian potential, were studied. Three possible pathways for nanoparticle capture were thus devised: viscous capture, Brownian capture and spontaneous capture. Spontaneous capture is proposed as the most favorable for nanoparticle capture during solidification of metal melt. The theoretical model of nanoparticle capture from this study will serve as a powerful tool for future experimental studies to realize exciting functionalities offered by bulk MMNCs.

Rapid control of phase growth by nanoparticles

Effective control of phase growth under harsh conditions (such as high temperature, highly conductive liquids or high growth rate), where surfactants are unstable or ineffective, is still a long-standing challenge. Here we show a general approach for rapid control of diffusional growth through nanoparticle self-assembly on the fast-growing phase during cooling. After phase nucleation, the nanoparticles spontaneously assemble, within a few milliseconds, as a thin coating on the growing phase to block/limit diffusion, resulting in a uniformly dispersed phase orders of magnitude smaller than samples without nanoparticles. The effectiveness of this approach is demonstrated in both inorganic (immiscible alloy and eutectic alloy) and organic materials. Our approach overcomes the microstructure refinement limit set by the fast phase growth during cooling and breaks the inherent limitations of surfactants for growth control. Considering the growing availability of numerous types and sizes of nanoparticles, the nanoparticle-enabled growth control will find broad applications.

Mechanical and thermal expansion behavior of laser deposited metal matrix composites of Invar and TiC

For laser assisted shape deposition manufacturing, residual stresses caused by the temperature gradient and material property mismatches result in part inaccuracy, warpage, or even delamination. The use of low coefficient of thermal expansion (CTE) materials such as Invar promises to reduce deformations caused by internal stresses. Thus, to obtain high quality of prototypes for molding and tooling, there is a need for a material with a low coefficient of thermal expansion, high yield strength, good toughness, and high wear resistance. This investigation concentrates on the development of laser-deposited composites of Invar and TiC. The experimental results show that the new materials yield exceptionally low CTE, high hardness and yield strength, and reasonable ductility. The class of materials studied in this work promises to reduce deformation caused by residual stresses and improves mechanical properties significantly.

Mechanical Properties and Microstructure of Mg∕SiC Nanocomposites Fabricated by Ultrasonic Cavitation Based Nanomanufacturing

Magnesium, the lightest structural metal, is of significance to improve energy efficiency in various applications. Mg/SiC nanocomposites were successfully fabricated by ultrasonic cavitation based dispersion of SiC nanoparticles in Mg melts. As compared to pure magnesium, the mechanical properties including tensile strength and yield strength of the MglSiC nanocomposites were improved significantly, while the good ductility of pure Mg was retained. The grain size of the pure magnesium was refined significantly when SiC nanoparticles were dispersed in the Mg matrix. In the microstructure of MglSiC nanocomposites, while there were still some SiC microclusters, most of the SiC nanoparticles were dispersed very well. Transmission electron microscopy study of the interface between SiC nanoparticles and magnesium matrix indicates that SiC nanoparticles bond well with Mg without forming an intermediate phase.

Investigation of heat generation in ultrasonic metal welding using micro sensor arrays

A lack of sensing techniques with desired spatial and temporal resolutions at critical locations has hindered the real-time monitoring of many manufacturing processes. Micro thin film sensors, when properly implemented, can offer tremendous benefits for real-time sensing in those processes. In this study, a batch production of micro thin film sensor arrays on nickel was realized by transferring thin film sensors from silicon wafers directly into nickel substrates through standard microfabrication and electroplating techniques. To demonstrate the potential applications, micro sensor arrays that consist of multiple thermocouples and thermopiles were designed, fabricated and transferred into the electroplated nickel to study temperature field and heat generation during meso-scale ultrasonic welding. Sensor arrays are arranged immediately adjacent to the meso-scale welding area for in situ temperature and surface heat flux measurements. With the high temporal and spatial temperature data, a numerical method was developed to estimate the time resolved heat generation at the welding interface.

Study on Embedding and Integration of Microsensors Into Metal Structures for Manufacturing Applications

Real time monitoring, diagnosis, and control of numerous manufacturing processes is of critical importance in reducing operation costs, improving product quality, and shortening response time. Current sensors used in manufacturing are normally unable to provide measurements with desired spatial and temporal resolution at critical locations in metal tooling structures that operate in hostile environments (e.g., elevated temperatures and severe strains). Microsensors are expected to offer tremendous benefits for real time sensing in manufacturing processes. Rapid tooling, a layered manufacturing process, could allow microsensors to be placed at any critical location in metal tooling structures. However, a viable approach is needed to effectively integrate microsensors into metal structures during the process. In this study, a novel batch production of metal embedded microsensor units was realized by transferring thin-film sensors from silicon wafers directly into nickel substrates through standard microfabrication and electroplating techniques. Ultrasonic metal welding (USMW) was studied to obtain optimized process parameters and then used to integrate nickel embedded thin-film thermocouple (TFTC) units into copper workpieces. The embedded TFTCs successfully survived the welding tests, validating that USMW is a viable method to integrate microsensors to metallic tool materials. Moreover, the embedded microsensors were also able to measure the transient temperature in situ at 50μm directly beneath the welding interface during welding. The transient temperatures measured by the metal embedded TFTCs provide strong evidence that the heat generation is not critical for weld formation during USMW. Metal embedded microsensors yield great potential to improve fundamental understanding of numerous manufacturing processes by providing in situ sensing data with high spatial and temporal resolution at critical locations.