Alumina Compacts Research Articles

Effect of Slow Cooling in Reducing Pore Size in a Sintered Powder Metallurgical 6061Aluminium Alloy

The usage of powder metallurgy aluminium compacts in lieu of ferrous components in automotives helps to lower vehicle weight. The major drawback in the commercially available press sintered aluminium alloy is porosity which is mainly dependent on the powder metallurgical process parameters such as compaction pressure, sintering temperature and cooling rate after sintering. In this paper the effect of particle size and furnace controlled cooling after sintering on porosity level and micro hardness of an elemental 6061 aluminium alloy has been investigated. Aluminium particle sizes of 20 µm and 150 µm were used. The elemental 6061 aluminium alloy powders are warm compacted at 175 MPa. After sintering for about one hour at 600°C, the aluminium compacts were furnace cooled at the rate of 1°C /min to different temperatures of 500°C, 400°C, 300°C and 200?C. When the cooling temperature after sintering inside the furnace is effected at various temperatures from 600°C to 200°C, for a precipitate hardened aluminium compacts with aluminium particle size of 20 µm, the porosity level reduced by 26% and that for aluminium particle size of 150µm, the porosity level reduced by 23%. Marked improvement in micro hardness value is also observed correspondingly.

Transparent Alumina/Ceria Nanocomposites By Spark Plasma Sintering

AbstractThe influence of oxides (such as MgO, TiO2, CaO, etc.) on the transparency of polycrystalline alumina compacts are widely studied in the literature. In this work, a completely different approach is developed, consisting of precipitating 0.5 wt.‐% CeO2 nanoparticles (< 5 nm) on the surface of the starting alumina nanopowder (d50 approximately 170 nm) using cerium(III) acetate as precursor. It is shown that the ceria nanoparticles strongly enhance the transparency of the spark plasma sintered compacts due to: i) the ceria nanoparticles acting as powder lubricant, increasing by around 15% the initial density of the powder in the SPS die, and, ii) the CeO2 nanoparticles, having a very low solid solubility in the alumina grains, locating at grain boundaries, hindering alumina grain growth by pinning during SPS sintering at 1 430 °C, 80 MPa for 2 min. This effect is found to be effective only under SPS vacuum conditions. In order to explain the light scattering behavior in the near‐infrared and visible range, a light scattering model under the Rayleigh‐Gans‐Debye approximation for polycrystalline alumina is used. This model offers an additional and simple tool for a completed bulk evaluation of the SPS compacts microstructure.

Microwave fast sintering of submicrometer alumina

Commercially available alumina powder with high-purity submicrometer particle size and narrow particle size distribution was fully densified by a microwave hybrid fast firing technique. The alumina compacts were surrounded by susceptor material, which helped the heating of the samples, and sintered in a microwave oven at a frequency of 2.45 GHz and a power level of 1.8 kW. The sintered samples reached densities of 99% in sintering cycles of 30 to 40 minutes, a much shorter time than conventional sintering processes. The sintered samples showed uniform microstructures with powder particle size/average grain size rations higher than 1:2.

Carbon nanotube/boehmite-derived alumina ceramics obtained by hydrothermal synthesis and spark plasma sintering (SPS)

Preparation, structure and properties of hydrothermally treated carbon nanotube/boehmite (CNT/γ-AlOOH) and densification with spark plasma sintering of Al 2O 3 and CNT/Al 2O 3 nanocomposites were investigated. Hydrothermal synthesis was employed to produce CNT/boehmite from an aluminum acetate (Al(OH)(C 2H 3O 2) 2) and multiwall-CNTs mixture (200 °C/2 h.). TEM observations revealed that the size of the cubic shape boehmite particles lies around 40 nm and the presence of the interaction between surface functionalized CNTs and boehmite particles acts to form ‘nanocomposite particles’. Al 2O 3 and CNT/Al 2O 3 compact bodies were formed by means of spark plasma sintering (SPS) at 1600 °C for 5 min using an applied pressure of 50MPa resulting in the formation of stable α-Al 2O 3 phase and CNT–alumina compacts with nearly full density. It was also found that CNTs tend to locate along the alumina grain boundaries and therefore inhibit the grain coarsening and cause inter-granular fracture mode. The DC conductivity measurements reveal that the DC conductivity of CNT/Al 2O 3 is 10 −4 S/m which indicate that there is a 4 orders of magnitude increase in conductivity compared to monolithic Al 2O 3. The results of the microhardness tests indicate a slight increase in hardness for CNT/Al 2O 3 (28.35 GPa for Al 2O 3 and 28.57 GPa for CNT/Al 2O 3).

Optical Properties of Transparent MgO-Doped Alumina Fabricated by Spark Plasma Sintering

The microstructure and optical properties are investigated for MgO-doped alumina fabricated by spark plasma sintering at temperatures between 1100 and 1550 °C. The MgO doping renders the microstructure less sensitive to the sintering temperature by suppressing grain growth, whereas it has no significant effect on the densification of alumina and resultantly no effect in enhancing the total forward transmission. The value of the total forward transmission can be used as an indirect measure of the slight change in density.

Effects of microwave heating in nanostructured ceramic materials

This paper studies the influence of microwave heating on mass transport phenomena and phase transformations in nanostructured ceramic materials. Faster mass transport that depends significantly on the microwave field intensity is observed during microwave annealing of nanoporous alumina membranes. The effect of the microwave field on phase transformations and pore structure evolution in alumina powder compacts is characterized quantitatively. Preferred orientation of pores in ceramics sintered under linearly polarized microwave radiation is predicted theoretically and demonstrated experimentally. Decrease in the activation energy of plastic deformation is experimentally observed for alumina-based ceramics under microwave heating.

High-temperature strength of compacted sub-micrometer aluminium powder

Aluminium powders with a mean particle size of around 1 μm were compacted by cold isostatic pressing (CIP) and additional forging. The specimens are characterized by hot compression tests, dilatometry and metallography. A 3D interconnected structure of alumina films <5 nm in thickness is observed by transmission electron microscopy and field emission gun scanning electron microscopy; it is associated with the natural oxide skin which covers every aluminium powder and occupies around 3 vol.%. The compression tests are carried out in the range of 350–520 °C at strain rates of 0.003–3 s −1. The compressive strength was 100–150 and 130–180 MPa for the CIPed and forged samples, respectively. The low strain rate sensitivity m (<0.08) suggests that the alumina network forms a barrier, which suppresses any restoration mechanism across the grain boundaries as well as grain boundary sliding during hot deformation. The high strength of such compacted sub-micron Al powder is attributed to the conservation of a 3D alumina closed cell network filled with elastoplastic aluminium.

다입자유한요소법을 이용한 Al분말 압축공정에서 입자의 거동과 변형에 관한 연구

This paper describes multiparticle finite element model (MPFEM)-based powder compaction simulations performed to demonstrate the densification of compacted aluminum powders. A 2D MPFEM was used to explore the densification of a collection of aluminum particles with different average particle sizes under various ram speeds. Individual particles are discretized using a finite element mesh for a detailed description of contact mechanics. Porous aluminum powders with average particle sizes of and were compressed uniaxially at ram speeds of 5, 15, 30, and 60 mm/min by using an MTS servo-hydraulic tester. The slow ram speed was of great advantage to powder densification in low compaction force due to sufficient particle rearrangement. Owing to a decrease in the average particle size of aluminum, the compaction force increased.

Fabrication of porous alumina ceramics having cell windows with controlled size by PMMA template method

Highly porous alumina compacts have been prepared by filling alumina slurry into opening of a specially designed template block prepared by cross-linked (cl-) polymethylmethacrylate (PMMA) microspheres (mean particle size: 98.6 μm) under reduced pressure, followed by firing to remove the template and then sintering at 1600 °C. The template blocks were prepared by utilizing cl-PMMA and acetone solution dissolving noncrosslinked (Ncl-) PMMA as an adhesive to make partial connection among the cl-PMMA microspheres. Furthermore, the effects of the addition of other chemicals (two types of triblockcopolymers and a nonionic surfactant) to the Ncl-PMMA adhesive solution were tested to improve the wettability of the solution to cl-PMMA and then to control the cell windows among the cl-PMMA-originated cells after the firing. By employing the template block, prepared with the adhesive solution containing an appropriate amount of triblockcopolymer, a highly porous alumina compact having an open porosity of 77.2%, a mean cell window diameter of 28.8 μm, and strong alumina skeleton could be fabricated.

Co-precipitated ZnAl2O4 spinel precursor as potential sintering aid for pure alumina system

Abstract Ultra-fine ZnAl 2 O 4 spinel hydrogel precursor synthesized from mixed salt solutions of Zn 2+ and Al 3+ ions using ammonium hydroxide–hexamethylenetetramine as basic media for co-precipitation was used as bonding material and sintering aid for pure alumina system. The hydrogel powder exhibited some well-defined ZnAl 2 O 4 spinel phases at 800 °C. Alumina compacts were fabricated by incorporating small proportions of the precursor in alumina powder and firing at different temperatures (1350–1500 °C). The degree of densification was studied by measurement of fired shrinkage, apparent porosity, bulk density and cold crushing strength. Phase compositions and microstructural features of sintered samples were evaluated by XRD and SEM respectively. Addition of 0.2% hydrogel powder to alumina exhibited remarkable influence on development of high mechanical strength. The in situ formed ZnAl 2 O 4 spinel dopant acted as a grain growth inhibitor in the alumina system.

Microwave Sintering – A Novel Approach to Powder Technology

The present paper focus on preliminary work carried out at INETI concerning the use of microwave radiation applied to sintering of both ceramic and metal powders. Due to the characteristics of materials-radiation interaction, microwaves can become an interesting power source in powder technology and other processing routes, since it is possible to lower the sintering temperature and shorten the sintering cycles, leading to time and energy savings. Alumina, hydroxyapatite, titanium and stainless steel powder compacts were sintered in a modified commercial oven of 2.45GHz and 1000W nominal power. Microwave susceptors were used to enable temperature rise during the initial stage of the sintering cycles. Results on densification and microstructural evaluation of microwave sintered samples are reported and compared to conventionally sintered ones, when available. For similar porosity levels upon sintering, microwave radiation generally reduces sintering times from several hours to minutes. The results obtained so far are quite encouraging since in the case of alumina and stainless steel compacts, a decrease of about 200°C in the sintering temperature was achieved. It was also found that the green density plays a key role in the densification of both metallic and ceramic powders.

Effect of Dual Reinforcement on Wear Resistance by Aluminum Compacts Reinforce by SiC, Al2O3

Effect of Dual Reinforcement on Wear Resistance by Aluminum Compacts Reinforce by SiC, Al2O3

Densification of Alumina Powder by Using PECS Process with Different Pulse Electric Current Waveforms

Densification and sample temperature of alumina (Al2O3) powder during pulsed electric current sintering with different pulse power generators, inverter type and pulsed direct current type were investigated. The sample temperature for inverter generator was higher than that for pulsed direct current generator in same die temperature ranging form 800 to 1400oC. The relative density increased with increasing of the sample temperature.

Foaming behavior of Ti6Al4V particle-added aluminum powder compacts

The foaming behavior of 5 wt.% Ti6Al4V (Ti64) particle (30–200 μm)-added Al powder compacts was investigated in order to assess the particle-addition effects on the foaming behavior. Al compacts without particle addition were also prepared with the same method and foamed. The expansions of Ti64 particle-added compacts were measured to be relatively low at small particle sizes and increased with increasing particle size. At highest particle size range (160–200 μm), particle-added compacts showed expansion behavior similar to that of Al compacts without particle addition, but with lower expansion values. Expansions studies on 30–45 μm size Ti64-added compacts with varying weight percentages showed that the expansion behavior of the compacts became very similar to that of Al compact when the particle content was lower than 2 wt.%. However, Ti64 addition reduced the extent of drainage. Ti64 particles and TiAl3 particles formed during foaming increased the apparent viscosity of the liquid foam and hence reduced the flow of liquid metal from cell walls to plateau borders. The reduced foamability in the compacts with the smaller size Ti64 addition was attributed to the relatively high viscosities, due to the higher cumulative surface area of the particles and higher rate of TiAl3 formation between liquid Al and Ti64 particles.

Reduced responses of macrophages on nanometer surface features of altered alumina crystalline phases

Extensive prolonged interactions of inflammatory cells (such as macrophages) at the host–implant interface may lead to implant failure. While previous studies have shown increased in vitro and in vivo bone cell adhesion, proliferation and mineralization on nanophase compared to currently implanted ceramics, few studies have been conducted to elucidate inflammatory cell responses on such nanophase ceramics. Controlling surface feature size and corresponding surface roughness on implants may clearly alter immune cell responses, which would be an extremely important consideration for the use of nanostructured materials as improved biomaterials. In this study, reduced macrophage density was observed on alumina (Al 2O 3) compacts with greater nanometer surface roughness accompanied by changes in crystallinity for up to 24 h in culture. Since alumina is a commonly used ceramic in orthopedic applications, this in vitro study continues to support the use of nanophase ceramics as improved orthopedic implants by demonstrating reduced macrophage responses.

Using microwaves to synthesize pure aluminum and metastable Al/Cu nanocomposites with superior properties

The processing of aluminum using powder metallurgy techniques is a challenging task due to the presence of thin oxide films on the surface of the metal particles which prevent strong bonding between particles during sintering. In this study, an innovative hybrid microwave sintering technique is utilized to process pure aluminum and Al/Cu nanocomposites without the need of any protective atmosphere. Hybrid microwave sintering involves the heating of aluminum compacts using both microwave energy and radiant heating. Significant savings in time and energy can be achieved using the fabrication methodology. Results revealed that processing methodology used in this study provides a simple and inexpensive option to existing processing methodologies to synthesize pure Al and Al/Cu nanocomposites with superior combination of properties.

Master sintering curves of two different alumina powder compacts

Concept of Master Sintering Curve is a strong tool for optimizing sintering schedule. The sintering behaviour can be predicted, and sintering activation energy can be calculated with the help of few dilatometric measurements. In this paper an automatic procedure was used to calculate Master Sintering Curves of two different alumina compacts. The sintering activation energies were determined as 640 kJ/mol for alumina with particle size of 240 nm, respective 770 kJ/mol for alumina with particle size of 110 nm. The possibility to predict sintering behaviour with the help of Master Sintering Curve was verified. .

Effect of Segregation of a Polyacrylic Acid (PAA) Binder on the Green Strength of Dry‐Pressed Alumina Compacts

A polyacrylic acid (PAA) binder with both binder and disperser properties was applied to prepare alumina granules with and without a segregated binder layer (SBL) to investigate an SBL's effects on the mechanical properties of dry‐pressed alumina green compacts. The formation of SBLs in granules was based on the production of free, unadsorbed PAA ionic molecules in the liquid phase. The green strength of the alumina compact showed a significant increase as SBLs formed. Adequate forming conditions lead to squeezing out of the binder and redistribution of SBLs to bind granules together, thus enhancing the green strength of the compact and successfully eliminating intergranular pores and granule relics.

The effect of different powder particle size on mechanical properties of sintered alumina, resin‐ and glass‐infused alumina

In this study, the compaction and sintering behavior of fine alumina powders of different particle sizes and the effect of matrix particle size on biaxial strength and fracture toughness of infused matrices were investigated. Three different alumina powders, In-Ceram alumina, A16SG, and RC172 were selected, representing a range of particle size and shape. RC172 and A16SG were dry-pressed. In-Ceram alumina was slip-cast following manufacturer's recommendations. Dry-pressed ceramic blocks were sectioned into disks with a thickness of 1.5-mm. Uninfused disks were sintered at four temperatures between 1250 degrees C and 1400 degrees C. For glass or resin infused specimens, alumina disks were sintered at 1250 degrees C for 2 h and separated into two groups for glass infusion and resin (UDMA/TEGDMA) infusion. Disks were tested for biaxial flexural strength with a universal testing machine (Instron) at 0.5-mm/min crosshead speeds. One-way ANOVA and Duncan's multiple range tests revealed that alumina disks with different smaller particle sizes have significantly higher biaxial strength (p < 0.05). The strength of the alumina matrix was greatly increased by glass and resin infusion. The biaxial strength of resin-infused alumina increased as particle size decreased, whereas strength of glass-infused alumina was constant.

Suppression of grain growth in sub-micrometer alumina via two-step sintering method

Two-step sintering (TSS) was applied to suppress the accelerated grain growth of sub-micron (∼150 nm) alumina powder. The application of an optimum TSS regime led to a remarkable decrease of grain size down to ∼500 nm; while the grain size of the full-dense structures produced by conventional sintering ranged between 1 and 2 μm. To find how important the temperatures at sintering steps might be, several TSS regimes were conducted. The results showed that the temperatures at both sintering steps play vital roles in densification and grain growth of the alumina compacts. Based on the results, the optimum regime consisted of heating the green bodies up to 1250 °C (first step) and then holding at 1150 °C for more than 60 h (second step). This yielded the finest microstructure with no deterioration of the densification. Heating at 1300 °C (first step) and then at 1200 °C (second step) was not a successful procedure. Lowering the temperature of the second step down to 1100 °C resulted in exhaustion of the densification at 88% -theoretical density. A nearly full-dense structure with an average grain size of 850 nm was obtained when the temperature of the second step was increased to 1150 °C. Empirical results show that not only the first step temperature has to be high enough to reach a structure containing unstable pores, but the second sintering temperature must also be high enough to activate the densification mechanism without grain growth. This means that a considerable densification at the first step does not imply enough second-step densification.