Papers by Author: Jai Sung Lee

Abstract: Powder Injection molding (PIM) is a cost-effective process for the fabrication of complex shaped parts, and has a great potential in many applications. In this work, an improved wax-based binder was developed for the powder injection molding of TiH₂ powder fabricated by recycling of Ti chip. Fine TiH₂ powders of about 350 nm in particle size were produced by attrition milling of Ti chip in less than five minutes, resulting from simultaneous self-propagating High temperature Synthesis (SHS) and fracturing. TiH₂ feedstock, a mixture of binder and powders, was fabricated with critical powder loading of 68 vol.%. The rheological characteristics of the feedstock were investigated for subsequent processing step. Viscosity of the feedstock showed pseudo-plastic flow behavior and to optimize injection molding parameter, in-mold rheology curve was generated. The results indicated that the recycled TiH₂ feedstock can be used for the fabrication of the complex shaped parts with good shape.

Abstract: The present investigation attempted to optimize the R-D (reduction-diffusion) process for fabricating Sm2Fe17 nanoscale powder from ball-milled powders of samarium oxide and iron oxide using a solid reducing agent of calcium hydrides (CaH2). It was found that the target alloy phase of Sm2Fe17 can be produced by controlling the gas atmosphere in the process of powder preparation to R-D reaction. Powder handling of CaH2 in a protective atmosphere is essential to avoid the formation of Ca(OH)2 which suppresses calcium formation. A switching gas atmosphere of H2 to Ar-H2 during the R-D process at 350oC resulted in a reduction of Fe2O3 and alloying of Sm-Fe, consequently forming nanocrystalline Sm2Fe17.

Abstract: The key concept of nanopowder agglomerate sintering (NAS) process is based on the optimization of structure design and full density processing of nanopowder into nanostructured micro-components. The kinetics of NAS process is characteristic of being controlled by material transport through hierarchical interface structures of nanopowder agglomerates. Through optimal design of those hierarchical interfaces such as nano grain boundary and agglomerate boundary, thus, full density nanopowder materials can be fabricated by pressureless sintering. In this paper we overview recent studies on the role of hierarchical interfaces for processing of full density nanopowder materials.

Abstract: Calciothermic reduction-diffusion (CRD) method was employed to prepare the Sm2Fe17 powder. By using CRD method, single-phase Sm2Fe17 powders were successfully made and no α-Fe phase detected. And Subsequent suitable nitrogenation treatment after CRD process enabled us to obtain Sm2Fe17Nx magnetic powders. However, the magnetic performance of the powders was below expectation due to their large particle size. Further study on effective milling process is needed.

Abstract: The radiotracer technique was applied to measure self- (Fe, Ni) and solute- (Ag) grain boundary diffusion in nanocrystalline Fe-40wt.%Ni alloy. The nanocrystalline material was prepared by pressureless sintering of the nanoalloy powders. The nano-sized crystallites were found to be clustered in micrometer-large agglomerates. Two types of internal interfaces with fundamentally different properties exist in the nanomaterial: the grain boundaries between the nanocrystallites and the interfaces between the agglomerates. A complete and consistent model of the diffusion processes in such material is elaborated. Whereas the nanocrystalline boundaries reveal diffusivities, which are similar to those in coarse-grained material, diffusion along interagglomerate interfaces occurs faster by orders of magnitude. This behavior is explained by a nonrelaxed structure of the inter-agglomerate interfaces.

Abstract: This paper overviews our recent investigations on the processing of net-shaped Fe-based nanoparticulate materials and their related material properties such as mechanical and corrosion properties. The key-process for fabricating fully densified net-shaped nanopowder by pressureless sintering is an optimal control of agglomerate size of nanopowder. Enhanced mechanical property of powder injection molded Fe-Ni nanopowder could be explained by grain refinement and uniformity of microstructure.

Abstract: Densification behavior of nano-agglomerate powder during pressureless sintering of Fe-Ni nanopowder was investigated in terms of diffusion kinetics and microstructural development. To understand the role of agglomerate boundary for sintering process, densification kinetics of Fe-Ni nano-agglomerate powder with different agglomerate size was investigated. It was found that activation energy for densification process was lower in the small-sized agglomerate powder. The increase in the volume fraction of inter-agglomerate boundary acting as high diffusion path might be responsible for the enhanced diffusion process.

Abstract: The present investigation has attempted to optimize hydrogen reduction process for the mass production of Fe-8wt%Ni nanoalloy powder from Fe2O3-NiO powder. In-situ hygrometry study was performed to monitor the reduction behavior in real time through measurement of water vapor outflowing rate. It was found that the reduction process can be optimized by taking into account the apparent influence of water vapor trap in the reactor on reduction kinetics which strongly depends on gas flow rate, reactor volume and reduction.

Abstract: Synthesis of iron nanopowder by room-temperature electrochemical reduction process of α-Fe2O3 nanopowder was investigated in terms of phase evolution and microstructure. As process variables, reduction time and applied voltage were changed in the range of 1~20 h and 30~40 V, respectively. From XRD analyses, it was found that volume of Fe phase increased with increasing reduction time and applied voltage, respectively. The crystallite size of Fe phase in all powder samples was less than 30 nm, implying that particle growth was inhibited by the reaction at room temperature. Based on the distinct equilibrium shape of crystalline particle, phase composition of nanoparticles was identified by TEM observation.

Abstract: The influence of reaction temperature on phase evolution of iron oxide hollow nanoparticles during chemical vapor condensation (CVC) process using iron acetylacetonate was investigated. X-ray diffraction (XRD) analyses revealed that three iron oxide phases (α-Fe2O3, γ-Fe2O3, and Fe3O4) and a mixture of β-Fe2O3 and small amount of γ-Fe2O3 were synthesized at 700oC and 900oC, respectively. TEM observation disclosed that the iron oxide particles are almost composed of hollow structured nanoparticles of 10~20 nm in size and 3~5 nm in shell thickness. This result implies that reaction temperature determining various reaction parameters plays an important role for the phase- and structural evolutions of iron oxide hollow nanoparticles. Especially, the present investigation attempted to explain temperature dependence of the phase evolution of β-Fe2O3 hollow nanoparticles in association with the decomposition of iron acetylacetonate.