Ball Milling Research Articles

Effect of La on Microstructure, Mechanical Properties and Friction Behavior of In Situ Synthesized TiB2/6061 Composites

In situ synthesized 3 wt.%TiB2/6061 composites with different La contents were fabricated by an Al-K2TiF6-KBF4 system at 850 °C with ball milling and stirring casting. The effects of La content (0 wt.%, 0.1 wt.%, 0.3 wt.%, 0.5 wt.%) on the microstructures and mechanical properties of the composites at room temperature were investigated. The results showed that the addition of La could refine α-Al grains and modify the morphology of TiB2 particles significantly. In 0.3 wt.%La-3 wt.%TiB2/6061 composites, there are chamfering planes on the surface of TiB2 particles, which are caused by the adsorption of La on the {112¯0}, {12¯12} and {101¯1} crystal planes. The values of YS, UTS and EL of the composites with 0.3 wt.% La were 216.8 MPa, 273.0 MPa and 11.2%, which were 69.2%, 34.8% and 5.7% higher than those of the 3 wt.%TiB2/6061 composites. The improvement of mechanical properties was mainly attributed to the grain refinement, distributed particles and transformation of particle morphology. In friction behavior, 0.3 wt.%La-3 wt.%TiB2/6061 composites have the best wear resistance properties with the smallest and shallowest grooves on the surface after wearing. The main mechanisms of the composites are adhesive wear and abrasive wear. In summary, the best content of La addition in 3 wt.%TiB2/6061 composites is 0.3 wt.%.

Waste to Wealth: One-Step Exfoliating of Spent Graphite to Build a Low-Cost Cathode for Lithium-Sulfur Batteries.

With the booming development of Li-ion batteries (LIBs), the recycling and reusing of spent graphite (SG) from LIBs is becoming increasingly crucial. Meanwhile, developing low-cost and efficient carbon hosts for lithium-sulfur (Li-S) batteries has gained widespread attention in the past decade. Nevertheless, the processing of carbon materials as sulfur hosts is often energy-consuming and complex. Herein, a simple and environmental-friendly strategy is proposed to reuse the SG to prepare graphene/sulfur composite cathode for Li-S batteries. Due to expanded layer spacing and defects of SG, sulfur molecules can strip it into a graphene-type host via ball milling. By optimizing the S/SG ratio and ball milling time, the as-prepared graphene/sulfur composite cathode with 70 wt.% sulfur content exhibits a high capacity of 1000 mAh g-1. With a high sulfur loading of 4.68 mg cm-2, the graphene/sulfur cathode can maintain 526 mAh g-1 after 400 cycles. This work provides a novel waste-to-wealth perspective for recycling spent graphite from LIBs to reuse in Li-S batteries.

Interface-driven microwave absorption enhancement in Mn-optimized Co2FeAl1-xMnx Heusler alloys

To address the urgent need for efficient and stable electromagnetic wave absorbing materials for electromagnetic interference (EMI) protection, we synthesized Co2FeAl1−xMnx Heusler soft magnetic alloys using a high-energy planetary ball milling method. We comprehensively analyzed their structural characteristics, surface morphology, magnetic properties, and electromagnetic parameters to explore their potential in electromagnetic wave absorption. The results show that incorporating manganese (Mn) significantly changes the alloys' crystal structure, surface morphology, and magnetic properties, greatly enhancing their wave absorption performance. The Mn doping specifically alters the surface morphology, which plays a crucial role in influencing the wave absorption characteristics of the Heusler alloys. When the Mn content increased to 25 %, the sample exhibits superior wave absorption, achieving the maximum reflection loss of −44.83 dB at 13.68 GHz with a thickness of 1.5 mm and an effective absorption bandwidth of 5.52 GHz. With a significant increase in the aspect ratio and noticeable changes in surface morphology, the sample with 75 % Mn content shows exceptional performance with an effective absorption bandwidth of 5.68 GHz, representing the highest effective absorption bandwidth in single-phase Heusler alloys. The Mn doping strategy effectively improves the material's impedance matching by adjusting its permittivity and permeability, facilitating multiple polarization relaxation mechanisms and significantly enhancing the alloys' electromagnetic wave absorption efficiency. Our study provides detailed experimental data for optimizing the electromagnetic wave absorption characteristics of Heusler alloys, verifies their practical application potential, and paves the way for developing new high-performance electromagnetic wave absorbing materials.

Mechanical (ball milling) activation to regulate microstructure of κ-carrageenan and improve freeze-thaw stability of κ-carrageenan gels and κ-carrageenan-based emulsion gels

To expand the wide range of applications of κ-carrageenan in the food and biomedical fields, we have physically modified the carrageenan and focused on its freeze-thaw stability. In this study, κ-carrageenan (KC) was modified by mechanically activated to prepare wet ball milling κ-carrageenan (WMKC), and its properties were determined. The research results indicate that mechanical activation helps improve the freeze-thaw stability of KC gels and enables KC to better maintain its gel network structure during the freeze-thaw process. These phenomena are related to the effects of mechanical activation on the particle morphology, molecular structure, molecular interactions, and moisture migration of κ-carrageenan. The particle morphology images demonstrated that the WMKC particles exhibited a more irregular surface, which facilitated greater penetration of water molecules into the interior of the κ-carrageenan particles. Furthermore, the results of molecular structure and molecular interaction analyses showed that mechanical activation resulted in the removal of sulfate groups from the κ-carrageenan molecular chain. This resulted in more free -OH being exposed on the molecular chain, which in turn provided more binding sites for KC molecules with water molecules. Low-field nuclear magnetic resonance (LF-NMR) results also proved that WMKC could better maintain the binding with water molecules during the freeze-thaw process. A better combination of WMKC molecules and water molecules can significantly diminish the irreversible damage to the gel network structure of WMKC during the freeze-thaw process, thereby effectively enhancing the freeze-thaw stability of WMKC. In addition, we further used WMKC as the gel matrix and investigated that the freeze-thaw stability of the WMKC-based emulsion gel was optimal when the mechanical activation duration was 3h, which well meets the demand of κ-carrageenan emulsion gels in the frozen food industry.

Enhancing Long Stability of Solid-State Batteries Through High-Energy Ball Milling-Induced Decomposition of Sulfide-Based Electrolyte to Sulfur.

Metal sulfides are increasingly favored as cathode materials in all-solid-state batteries (ASSBs) due to their high energy density, stability, affordability, and conductivity. Metal sulfides often exhibit capacities exceeding their theoretical limits, a phenomenon that remains not fully understood. In this study, it reveals that this phenomenon is primarily due to the sulfur decomposition from sulfide-based electrolyte. By employing the high-energy ball milling (HEBM) technique, the deposition of sulfide-based electrolyte onto sulfur is intentionally promoted, resulting in higher charge capacities compared to the discharge capacities and surpass theoretical limits of metal sulfides. Using chromium sulfide (Cr2S3) as the active material, the sulfur decomposed from sulfide-based electrolyte transforms into lithium sulfide (Li2S) after discharge, resulting in an increased capacity by ≈439.6 mAhg-1 and improved cycling stability. Consequently, it demonstrates a specific capacity surpassing 1200 mAh g-1 with a capacity retention of over 80% after 650 cycles, maintaining cycling stability for more than 1900 cycles and achieving a Coulombic efficiency exceeding 99.9%. This versatile HEBM approach enables the fabrication of ASSBs utilizing various transition metal sulfides, such as molybdenum disulfide (MoS2), niobium disulfide (NbS2), and iron disulfide (FeS2), all exhibiting over theoretical limited capacities and prolonged cycling capabilities.

A composite anode based on intercalation and conversion mechanism for high-rate lithium-ion batteries

To increase the specific capacity and cycle stability of lithium-ion batteries at high current density, we have investigated the anode materials. Among them, black phosphorus has attracted attention because of its large theoretical specific capacity (2596 mA h/g). However, the moderate conductivity of black phosphorus itself makes it less effective. The addition of graphite to form P-C and P-O-C bonds with black phosphorus enhances the performance of the battery cell. Lithium ions are primarily stored in black phosphorus-graphite layered structural materials via an intercalation mechanism, which improves electrochemical performance at tiny current density but is inadequate for charge/discharge cycling at high current density. In addition, lithium ions also can undergo conversion mechanism with metal oxide materials (e.g. Tungsten trioxide). While this conversion mechanism enables more stable battery cycling at high current density, the specific capacity remains insufficiently high. Higher charge/discharge specific capacity and long cycle stability of lithium-ion batteries at high current density can be realized by the joint action of the two mechanisms. In this work, black phosphorus, graphite, and tungsten trioxide (BP/G/WO3) composites are prepared by ball milling method. A comprehensive series of electrochemical analyses reveals that the BP/G/WO3-532 electrode (BP, graphite, and WO3 mass ratio of 5:3:2) exhibits the most substantial enhancement in the cycling stability of lithium-ion batteries. The anode exhibits a high specific capacity of 1463.1 mA h/g at 6 A/g and presents a retention capacity of 1159.8 mA h/g after 300 charge/discharge cycles, indicating a high cycle stability and fast reaction kinetics. This result is mainly attributed to the joint action of two mechanisms of composites.

Multi-Feature Fusion and RF-Based Fault Diagnosis of Ball Mill Rolling Bearings

Multi-Feature Fusion and RF-Based Fault Diagnosis of Ball Mill Rolling Bearings

Reinforcement of recycled polypropylene by nano lanthana with improved thermal, mechanical and antimicrobial properties

Abstract In this study, lanthanum oxide (La2O3) nanoparticles or lanthana were synthesized by the planetary ball milling method and then used as a filler for the preparation of the polypropylene (PP) based nanocomposites by solution mixing method. The PP used in the study was derived from the discarded saline bottles. The structural and the surface morphology of the synthesized lanthanum oxide nanoparticles were characterized by XRD, SEM and FTIR. The thermogravimetric analysis (TGA) study revealed that the thermal stability of the nano lanthana composites increased with the addition of the lanthanum oxide nanoparticles. The mechanical properties, such as Young’s modulus and tensile strength, were also improved by the addition of the lanthanum oxide nanoparticles to the PP matrix. The composites also showed antibacterial activity against Escherichia coli bacteria. This approach not only mitigates medical plastic waste and environmental impact but also paves the way for versatile polymer nanocomposites with extensive industrial applications, especially in biomedical packaging.

Structural features of bimetallic composites of the Me-Al type (Cu, Ni, Nb), obtained by ball milling of powder mixtures and consolidation by torsion under pressure

A comparative study of the features of the microstructure of bimetallic composites of the Me-Al (Cu, Ni, Nb) type, obtained by ball milling of powder mixtures and consolidation by torsion under pressure in Bridgman anvils, was carried out. In all systems studied in this work, the formation of a nanoband structural state is observed, the elements of which are elongated predominantly along the direction parallel to the anvil plane. It has been established that in local areas characterized by the absence of the aluminum component, an SMC state without a nanolaminate structure is formed. An analysis of the features of structure formation was carried out taking into account the comparison of the characteristics of powder systems components (melting point, shear modulus and stacking-fault energy). It was shown that low shear modulus of aluminum, compared to other components, in combination with a higher homologous temperature, provides it high accommodative ability. It has been suggested that under conditions of torsion under pressure, the aluminum component, being a kind of solid lubricant, ensures slipping and flattening of stronger layers of the second component, which contributes to the formation of a nanolaminate structure in the metal‑aluminum systems under consideration.

Ball milling of pyrite in air to significantly promote the Fenton reaction: A mechanistic study

Natural pyrite (FeS2) has been widely used as heterogenous Fenton catalyst due to the unique iron supplying and ferrous regeneration performance, however, natural pyrite has poor catalytic activity due to the low surface reactivity. Ball milling is commonly used to modify pyrite, but the mechanism has not been thoroughly studied. In our work, by optimizing the ball milling conditions, the catalytic efficiency of modified pyrite is increased by 60 times compared to natural pyrite, and the ball milled pyrite Fenton system was able to degrade dyes and a series of antibiotics within 30 min. Compared to ball milling in nitrogen and vacuum, ball milling in air increased the proportion of S2− and active iron sites on the surface of pyrite, which assisted and accelerated the regeneration of ferrous and enhanced the iron supplying performance. This work explored the mechanisms of ball milling to modify the properties of pyrite, reported a green and efficient ball milled pyrite Fenton system, and provided a new insight in regulating ball milling conditions for mechanochemical modification.

Exploring the Effect of Ball Milling on the Physicochemical Properties and Oxygen Evolution Reaction Activity of Nickel and Cobalt Oxides

Ball milling is commonly used to reduce catalyst particle size. However, little attention is paid to further changes that ball milling can cause to the rest of the catalysts’ physicochemical properties, which can impact their intrinsic catalytic activity. The effect of ball milling on the physicochemical properties of NiCoO2, NiO, CoO, and NiO:CoO mixtures is reported and correlated with their electrochemical oxygen evolution reaction (OER) activity. It is also shown that particle fragmentation is an inherent consequence of ball milling, but some oxides can also experience a phase transformation. In the case of rocksalt‐structured CoO, it is partially or entirely transformed to spinel‐structured Co3O4. Additionally, NiCo2O4 with a spinel structure can be formed by ball milling NiO and CoO simultaneously (both rocksalt structures), but only in the absence of water. The changes impact the electrochemical activity of the initial oxides. Ball milled NiCoO2 exhibits the highest activity with a mean potential of 1.563 V at 10 mA cm−2, demonstrating the advantage of having Ni and Co in the same structure. Although NiCo2O4 is also a binary oxide, the results indicate that its metal coordination environment makes it intrinsically less active than NiCoO2 for the OER in alkaline media.

Advanced nano modification of ecofriendly glauconite clay for high efficiency methylene blue dye adsorption

This research focuses on the utilization of nano glauconite clay as an environmentally friendly sorbent for the removal of cationic dyes, particularly Methylene Blue (MB), from polluted water. The glauconite clay was sourced from the El Gidida region of Egypt and subjected to grinding in a laboratory-type ball mill to ensure homogeneity and increase the active sites available for the adsorption process. The resulting ball milled nano clay (BMNC) was characterized using techniques such as X-ray fluorescence (XRF), Fourier transform infrared (FT-IR) spectroscopy, transmission electron microscopy (TEM), energy dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). The concentration of MB dye was monitored using UV–Vis spectroscopy to assess the adsorption capacity of BMNC under various conditions including pH, time, dose, and temperature. The optimal conditions for the adsorption process were determined to be a pH range of 7–8, a contact time of 60 min, and a dose of 200 ppm, resulting in an adsorption capacity of 128 mg/g. This process demonstrated both low cost and high speed. The adsorption mechanism of MB on the BMNC surface was evaluated through kinetics, adsorption isotherms, and thermodynamics. The experimental data indicated an endothermic, spontaneous, and thermodynamically favourable adsorption process, which was further supported by simulated modelling results using Forcite program. The in-silico data aligned well with the experimental findings. Additionally, the study assessed the interference of salts, metal ions, and other dyes on MB adsorption onto BMNC, showing promising results. These findings strongly support the effectiveness of our sorbent substrate under challenging conditions.

Layered bismuthene forming the interfacial pathway for rapid charge transfer in CuNb13O33/g-C3N5 photocatalyst for enhancing ciprofloxacin degradation

The objective of the present research was to examine the usefulness of the photocatalytic degradation process in removing the ciprofloxacin drug from wastewater, which is difficult to remove from waterbodies. To tackle this difficulty, a ternary copper niobium oxide/carbon nitride/layered bismuthene heterostructure (CuNb13O33/g-C3N5-L-Bi) composite was developed by an intuitive solvothermal process. layered bismuthene (L-Bi) was prepared using a unique ball milling approach. According to the results of the characterization, adding L-Bi and g-C3N5 with a low band gap to the original band structure of CuNb13O33 makes it more efficient. After 120 min of irradiation, the modified CuNb13O33/g-C3N5-L-Bi sample significantly improved ciprofloxacin degradation, resulting in a degradation rate of 98 %. In addition, the impact of the catalyst that has been created on the removal of ciprofloxacin at various pH, catalyst dosages, and scavengers was also examined, demonstrating the catalyst’s suitability for purifying natural water environments. A detailed study of the steps used to break down ciprofloxacin has shown that many active species are involved, with a focus on the important roles played by reactive oxidative species (ROS). Thus, this study introduces a novel combination of layered bismuthene photocatalysts for environmentally friendly degradation of antibiotics.

Innovation in sustainable composite research: Investigating graphene-reinforced MMCs for liquid hydrogen storage tanks in aerospace and space exploration

The demand for lightweight materials in space exploration applications has seen a significant rise. This study presents a novel approach by integrating graphene with Aluminium alloy (AA) 2900 powder, synthesized through High energy ball milling technique. The resulting powder was used to reinforce Aluminium alloy 2195, creating metal matrix composites (MMCs) via squeeze casting. The findings demonstrate that incorporating 0.5 wt % 2D graphene nanoplatelets (2D-Grnp) in AA 2195 achieved density match, enabling homogeneous dispersion, addressing composite casting challenges. Consequently, the AA 2900 alloy embedded with 2D-Grnp facilitated the homogeneous dispersion of reinforcements during the squeeze casting process, yielding MMCs Ideal for potential use in lightweight liquid hydrogen fuel tank structures for launch vehicles. Following T8 heat treatment, the final casted composite plate exhibited significant enhancements in ultimate tensile strength, with a 4.5% increase over monolithic Al 2195-T8, exhibiting nominal reduction in elongation behavior and higher hardness. Additionally, scanning and transmission electron microscopy (SEM, TEM), Small Angle Neutron Scattering (SANS) and Electron Backscatter Diffraction (EBSD) revealed the squeeze casting technique's effectiveness by exhibiting enhanced bonding among homogeneously reinforced 2D-Grnp, T1/θ’ precipitates, and AA 2195.

Improving thermoelectric performance of Nickel substituted ZnSb alloy through carrier engineering and nanostructuring

Zn1-xNixSb (0 ≤ x ≤ 0.08) nanostructures were prepared by the planetary Ball milling technique. XRD analysis confirms the phase purity and orthorhombic crystal structure of the samples. FESEM analysis shows the spherical morphology of the Zn1-xNixSb samples. The EDX and elemental mapping analysis confirms the composition and elemental distribution of Zn1-xNixSb (0 ≤ x ≤ 0.08) alloys. HRTEM images clearly show the interfaced grains with grain boundaries. DRS-UV analysis revealed the narrowing of bandgap while increasing the Ni content in Zn site due to alloying effect. The synthesized Zn1-xNixSb alloys show low resistivity compared to pure samples due to high carrier concentrations. Seebeck coefficient of Zn1-xNixSb alloys were measured from room temperature to 635 K. A high-power factor of 1344 µW/m K2 was obtained for the Zn0.98Ni0.02Sb sample at 533 K compared to pristine ZnSb (574 µW/m K2 at 533 K). High thermoelectric figure of merit (zT) of 0.69 was achieved for Zn0.98Ni0.02Sb sample at 533 K compared to pristine ZnSb (zT of 0.34 at 533 K). The experimental results illustrated that Nickel substitution is a one of the possible ways to improve the thermoelectric figure of merit of ZnSb alloys.

Lyophilization strategy to synthesize ultrafine NaCl template for preparation of photocatalytic BiOCl nanoplates via chemical vapor deposition

Two-dimensional (2D) bismuth oxychloride (BiOCl) has attracted increasing attention in nanoelectronics, catalysis, energy storage, and the environment, attributed to its wide indirect band gap and large surface area. However, the imprecise control of the catalytic site on the substrate makes it challenging to produce 2D BiOCl in large quantities economically. Here, we developed lyophilization to create ultrafine NaCl templates to obtain a higher yield of 2D BiOCl nanoplates than traditional substrates using a chemical vapor deposition (CVD) method. In contrast to ball milling or recrystallization, lyophilization can produce the sodium chloride (NaCl) in the ice lattice domain, resulting in ultrafine NaCl particles after removing water. Moreover, the NaCl particles synthesized by lyophilization showed lower crystallinity with partially distorted structures, such as twisted octahedral structures and the structure with Na+ separated from other atoms by an ice lattice. In addition, our method offers an opportunity to introduce and engineer the oxygen vacancies (OVs) on 2D BiOCl to narrow the band gap, improve the separation of photogenerated carriers, and enhance their photocatalytic efficiency by 17.2 times. Thus, our work opens a new avenue to produce 2D BiOCl by tuning the substrate in CVD growth and inspires a new strategy to promote the performance of 2D photocatalysts.

Effect of SiC doping on microwave absorbing properties of ball-milled carbonyl iron/MoS2 composites

Using MoS2 to prepare novel composite absorbing coatings is an effective strategy to enhance electromagnetic wave absorption. In order to explore the preparation process of large-scale preparation of MoS2 composite absorbing materials, a Fe/MoS2/SiC laminated composite absorbing material was prepared by high-energy ball milling method to realize the absorption of electromagnetic waves. By adjusting the proportion of SiC, SiC, MoS2 and Fe were ball-milled at room temperature for 20 h, and the dielectric properties were improved to achieve good absorbing effect. The microstructure and properties of the materials were measured by XRD, SEM, Raman, XPS, HRTEM, VSM and VNA. The results show that the doping of appropriate amount of SiC reduces the interplanar spacing of MoS2 and increases the edge points, which increases the conductivity of MoS2. MoS2 reduces the number of layers and increases its size and area, which improves the dielectric properties of Fe/MoS2 and optimizes the electromagnetic parameters of the composites. When the ratio (mole) of SiC, Fe and MoS2 is 3:6:2, the best electromagnetic wave absorption effect is obtained, the lowest electromagnetic wave reflection loss is −72.98 dB, and the best bandwidth is 3.04 GHz when the matching thickness is 6.53 mm.

Mechanical processing of wet stored fly ash for use as a cement component in concrete

Wet storage effects on fly ash mean that processing may be necessary to achieve the physical properties required for use in concrete. This paper considers drying, de-agglomeration and milling of various wet stored fly ashes at laboratory and pilot/benchtop scales, towards meeting these. In the laboratory, different batch quantities and milling times with as-received/pre-screened materials were examined using a ball mill. Greater particle size reductions were obtained with increased milling time but at gradually reducing rates. Pre-screening and batch quantity had relatively minor effects on particle size reductions, with small differences also found between wet and dry stored fly ash. Extended milling time resulted in a darkening of colour; slight increases in loss-on-ignition, the main oxides content and crystalline components; reductions in water requirement (to a point); and greater reactivity. Similar effects were generally noted in concrete for the superplasticising admixture dose to achieve a target slump and compressive (cube) strength. At pilot/benchtop scale, a dryer-pulveriser and spiral jet mill were used, which gave general agreement with the behaviour noted in the laboratory, but with the effects tending to be less. Fineness levels in Standards were achievable, with subsequent performance in concrete, appearing to depend on the milling process used.

Application of DPG/KH550 modified pyrolysis carbon black in oil and high temperature‐resistant NBR composites

AbstractIn this paper, pyrolysis carbon black (CBp) was introduced into nitrile butadiene rubber (NBR), the effects of the ratio of CBp and carbon black (N326) on the properties of NBR composites were investigated, and the optimal ratio was determined. On this basis, the accelerator DPG, coupling agent KH550 and CBp were modified by ball milling and plasma. The results showed that when the ratio of CBp to N326 was 40:15, the overall properties of NBR composites was better. Compared with the unmodified CBp/NBR composites, the change rate of tensile product, resilience and DIN abrasion of ball milling‐plasma modified CBp/NBR composites in oil environment were reduced by 52.96%, 12.81%, and 27.19%, respectively, and the tear strength after double damage by high temperature and oil bath was increased by 15.63%, which resulted in better oil and high temperature‐resistance. In summary, the ball milling‐plasma combined with DPG/KH550 modified CBp can not only replace N326 carbon black, but also realize the preparation of NBR composites with better oil and high temperature‐resistance.

Mechanochemical Synthesis ofβ-Sulfenylated Ketones and Esters.

For the first time, ball milling has been employed in the solvent-free synthesis of sulfur-functionalized materials from thiols and α,β-unsaturated ketones and esters, using potassium carbonate as a transition metal-free catalyst. This environmentally friendly protocol makes use of easily accessible reagents to prepare β-sulfenylated carbonyl compounds with yields exceeding 91% under ambient air and solvent-free conditions. Additionally, this innovative synthetic strategy enables the modification of chalcones, compounds with significant medicinal and synthetic potential. The reactions are efficient and easily scalable to gram quantities, offering substantial benefits for practical applications.